r-j3ib mate maintenance manual for europe b-81525en-1-01

FANUC Robot series

MAINTENANCE MANUAL

B--81525EN--1/01

For Europe

R--J3iB Mate CONTROLLER

B--81525EN--1/01 Table of Contents

c--1

PREFACE p--1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

I SAFETY PRECAUTIONS

1. SAFETY PRECAUTIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.1 OPERATOR SAFETY 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1.1 Operator Safety 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.1.2 Safety of the Teach Pendant Operator 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.1.3 Safety During Maintenance 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 SAFETY OF THE TOOLS AND PERIPHERAL DEVICES 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2.1 Precautions in Programming 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2.2 Precautions for Mechanism 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3 SAFETY OF THE ROBOT MECHANISM 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3.1 Precautions in Operation 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3.2 Precautions in Programming 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3.3 Precautions for Mechanisms 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4 SAFETY OF THE END EFFECTOR 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4.1 Precautions in Programming 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5 SAFETY IN MAINTENANCE 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.6 WARNING LABEL 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

II MAINTENANCE

1. OVERVIEW 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. CONFIGURATION 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1 EXTERNAL VIEW OF THE CONTROLLER 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 COMPONENT FUNCTIONS 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 PREVENTIVE MAINTENANCE 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. TROUBLESHOOTING 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1 POWER CANNOT BE TURNED ON 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1.1 Teach Pendant Cannot be Turned On 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1.2 Initial Screen Remains on the Teach Pendant 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 ALARM OCCURRENCE SCREEN 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 SAFETY SIGNALS 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4 MASTERING 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5 TROUBLESHOOTING USING THE ERROR CODE 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6 TROUBLESHOOTING USING FUSES 92. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.7 TROUBLESHOOTING BASED ON LED INDICATIONS 96. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.8 POSITION DEVIATION FOUND IN RETURN TO THE REFERENCE POSITION(POSITIONING) 106. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.9 VIBRATION OBSERVED DURING MOVEMENT 107. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.10 MANUAL OPERATION IMPOSSIBLE 108. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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4. PRINTED CIRCUIT BOARDS 110. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.1 ROBOT CONTROLLER PC BOARD (A16B--3200--0450) 111. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 EMERGENCY STOP PC BOARD (A20B--1008--0022, --0023) 115. . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 BACKPLANE PC BOARD (A20B--2003--0330) 116. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. SERVO AMPLIFIERS 117. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.1 OUTLINE DRAWINGS 118. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.1 Power Supply Module PSM (A06B--6115--H001) 118. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.1.2 Servo Amplifier Module (A06B--6114--H205, A06B--6114--H302) 119. . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 LED OF SERVO AMPLIFIER 120. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.2.1 LED of Power Supply Module 120. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.2.2 LED of Servo Amplifier Module 121. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. SETTING THE POWER SUPPLY 122. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.1 BLOCK DIAGRAMS OF THE POWER SUPPLY 123. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2 CHECKING THE POWER SUPPLY UNIT 124. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3 CHECKING THE POWER SUPPLY MODULE 124. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.4 SELECTING THE TRANSFORMER CONNECTION 125. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7. REPLACING A UNIT 126. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.1 REPLACING THE PRINTED--CIRCUIT BOARDS 127. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.1 Replacing the Backplane Board (Unit) 128. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.1.2 Replacing the Robot Controller PC Board and Printed--Circuit Boards on the Backplane Unit 129. . . . . .7.1.3 Replacing the Emergency Stop PC Board 130. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.2 REPLACING CARDS AND MODULES ON THE ROBOT CONTROLLER PC BOARD 131. . . . . .

7.3 REPLACING THE TRANSFORMER 135. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.3.1 Replacing the Brake Power Transformer 135. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.3.2 Replacing the Power Transformer 136. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.4 REPLACING THE EMERGENCY STOP UNIT 137. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.5 REPLACING THE MAGNETIC CONTACTOR 138. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.6 REPLACING SERVO AMPLIFIERS 139. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.7 REPLACING THE TEACH PENDANT 140. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.8 REPLACING THE CONTROL SECTION FAN MOTOR 141. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.9 REPLACING THE FAN MOTOR OF THE SERVO AMPLIFIER CONTROL UNIT 142. . . . . . . . . .

7.10 REPLACING THE DOOR FAN UNIT AND HEAT EXCHANGER 143. . . . . . . . . . . . . . . . . . . . . . . .

7.11 REPLACING THE OPERATOR PANEL 144. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.12 REPLACING THE POWER SUPPLY UNIT 145. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.13 REPLACING A FUSE 146. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.13.1 Replacing a Fuse on the Robot Controller PC Board 146. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.13.2 Replacing a Fuse on the Emergency Stop PC Board 147. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.13.3 Replacing the Fuse on the Power Supply Module 148. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.13.4 Replacing the Fuse on the Servo Amplifier Module 149. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.14 REPLACING A RELAY 150. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.14.1 Replacing a Relay on the Emergency Stop PC Board 150. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.15 REPLACING BATTERY 151. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.15.1 Battery for Memory Backup (3 VDC) 151. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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III CONNECTION

1. GENERAL 155. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. BLOCK DIAGRAM 156. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. CONNECTION DETAILS 157. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1 CONNECTING THE POWER SUPPLY CABLE 158. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 FANUC I/O LINK 159. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 CONNECTING THE I/O LINK CABLE 161. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4 EMERGENCY STOP CIRCUIT 163. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.4.1 Emergency Stop Circuit Diagram 163. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.4.2 External Emergency Stop Input 164. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.4.3 External Emergency Stop Output 165. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5 CONNECTION OF SERVO AMPLIFIER 166. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6 CONNECTION OF ROBOT 167. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.7 CONNECTION OF TEACH PENDANT CABLE 168. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.8 CONNECTION OF CABLE FOR RS--232--C/RS--422 169. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.9 CONNECTING A CABLE TO A PERIPHERAL DEVICE 170. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.9.1 Peripheral Device Interfaces CRM79 and CRM81 170. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.9.2 When the Robot is Connected to the CNC by a Peripheral Device Cable 171. . . . . . . . . . . . . . . . . . . . . . .3.9.3 Digital I/O Signal Specifications 182. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.9.3.1 Peripheral device interface CRM 79 and CRM 81 182. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.9.4 Peripheral Device Cable Connector 184. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.9.5 Recommended Cables 185. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.10 END EFFECTOR INTERFACE 186. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10.1 Connecting the Mechanical Unit and End Effector 186. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10.2 Digital I/O Signal Specifications of End Effecter Control Interface 188. . . . . . . . . . . . . . . . . . . . . . . . . . .

3.11 TREATMENT FOR THE SHIELDED CABLE 189. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. TRANSPORTATION AND INSTALLATION 190. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.1 TRANSPORTATION 191. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 INSTALLATION 191. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 EXTERNAL CONTROLLER DIMENSIONS 192. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4 INSTALLATION CONDITION 193. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5 ADJUSTMENT AND CHECKS AT INSTALLATION 193. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6 NOTE AT INSTALLATION 194. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7 DISABLING HAND BREAK 194. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

APPENDIX

A. TOTAL CONNECTION DIAGRAM 197. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B. PERIPHERAL INTERFACE 208. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B.1 SIGNAL TYPES 209. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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B.2 I/O SIGNALS 210. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B.2.1 Input Signals 210. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B.2.2 Output signals 211. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B.3 SPECIFICATIONS OF DIGITAL INPUT/OUTPUT 212. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B.3.1 Overview 212. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B.3.2 Input/Output Hardware Usable in the R-J3iB Mate Controller 212. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B.3.3 Software Specifications 213. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C. OPTICAL FIBER CABLE 214. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B--81525EN--1/01 PREFACE

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PREFACE

This manual describes the following models.

Model Abbreviation

FANUC Robot LR Mate 100iB LR Mate100iB

FANUC Robot LR Mate 200iB LR Mate200iB

I SAFETY PRECAUTIONS

B--81525EN--1/01 1. SAFETY PRECAUTIONSSAFETY PRECAUTIONS

3

1 SAFETY PRECAUTIONS

For the safety of the operator and the system, follow all safety precautionswhen operating a robot and its peripheral devices installed in a work cell.

1. SAFETY PRECAUTIONS B--81525EN--1/01SAFETY PRECAUTIONS

4

Operator safety is the primary safety consideration. Because it is verydangerous to enter the operating space of the robot during automaticoperation, adequate safety precautions must be observed.

The following lists the general safety precautions. Careful considerationmust be made to ensure operator safety.

(1) Have the robot system operators attend the training courses held byFANUC.

FANUC provides various training courses. Contact our sales office for details.

(2) Even when the robot is stationary, it is possible that the robot is stillready to move state and is waiting for a signal. In this state, the robotis regarded as still in motion. To ensure operator safety, provide thesystem with an alarm to indicate visually or aurally that the robot isin motion.

(3) Install a safety fence with a gate so that no operator can enter the workarea without passing through the gate. Equip the gate with aninterlock that stops the robot when the gate is opened.

The controller is designed to receive this interlock signal. When the gate isopened and this signal received, the controller stops the robot in an emergency.For connection, see Fig.1.1.

(4) Provide the peripheral devices with appropriate grounding (Class 1,Class 2, or Class 3).

(5) Try to install the peripheral devices outside the work area.

(6) Draw an outline on the floor, clearly indicating the range of the robotmotion, including the tools such as a hand.

(7) Install a mat switch or photoelectric switch on the floor with aninterlock to a visual or aural alarm that stops the robot when anoperator enters the work area.

(8) If necessary, install a safety lock so that no one except the operatorin charge can turn on the power of the robot.

The circuit breaker installed in the controller is designed to disable anyone fromturning it on when it is locked with a padlock.

1.1OPERATOR SAFETY


5

(9) When adjusting each peripheral device independently, be sure to turnoff the power of the robot.

Safety gate which executes with opening the door.

Fig.1.1 Safety Fence and Safety Gate


6

The operator is a person who operates the robot system. In this sense, aworker who operates the teach pendant is also an operator. However, thissection does not apply to teach pendant operators.

(1) If it is not necessary for the robot to operate, turn off the power of therobot controller or press the EMERGENCY STOP button, and thenproceed with necessary work.

(2) Operate the robot system at a location outside the work area.

(3) Install a safety fence with a safety gate to prevent any worker otherthan the operator from entering the work area unexpectedly and alsoto prevent the worker from entering a dangerous area.

(4) Install an EMERGENCY STOP button within the operator’s reach.

The robot controller is designed to be connected to an external EMERGENCYSTOP button. With this connection, the controller stops the robot operationwhen the external EMERGENCY STOP button is pressed. See the diagrambelow for connection.

EMGIN1

Emergency stop P.C. board

Note) Connect to EMGIN1 and EMGIN2 are on the emergency stop P.C. board

External EMERGENCY STOP button

EMGIN2

Fig.1.1.1 Connection Diagram for External Emergency Stop Switch

1.1.1Operator Safety


7

While teaching the robot, it is necessary for the operator to enter the workarea of the robot. It is particularly necessary to ensure the safety of theteach pendant operator.

(1) Unless it is specifically necessary to enter the robot work area, carryout all tasks outside the area.

(2) Before teaching the robot, check that the robot and its peripheraldevices are all in the normal operating condition.

(3) When entering the robot work area and teaching the robot, be sure tocheck the location and condition of the safety devices (such as theEMERGENCY STOP button and the deadman switch on the teachpendant).

FANUC’s teach pendant has a switch for enabling or disabling the robot opera-tion from the teach pendant and a deadman switch in addition to the EMER-GENCY STOP button. The switches function as follows.

EMERGENCY STOP button : Pressing this button always brings the robotto an emergency stop, irrespective of thestate of the enable/disable switch.

Deadman switch : The function of this switch depends on thestate of the enable/disable switch.

In the enable position -- Releasing the deadman switch brings therobot to an emergency stop.

In the disable position -- The deadman switch is disabled.

Note)The deadman switch is provided to bring the robot to an emergencystop when the operator releases the teach pendant in an emergency.

(4) The teach pendant operator should pay careful attention so that noother workers enter the robot work area.

NOTEIn addition to the above, the teach pendant enable switch and thedeadman switch also have the following function.

By pressing the deadman switch while the enable switch is on, theemergency stop factor (normally the safety gate) connected toFENCE1 and FENCE2 of the controller is invalidated. In this case,it is possible for an operator to enter the fence during teachoperation without making the robot in the emergency stopcondition. In other words, the system understands that thecombined operations of pressing the teach pendant enable switchand pressing the deadman switch indicates the start of teaching.The teach pendant operator should be well aware that the safety gateis not functional under this condition and bear full responsibility toensure that no one enters the fence during teaching.

(5) When entering the robot work area, the teach pendant operator shouldenable the teach pendant whenever he or she enters the robot workarea. In particular, while the teach pendant enable switch is off, makecertain that no start command is sent to the robot from any operatorpanel other than the teach pendant.

The teach pendant, operator panel, and peripheral device interface send eachrobot start signal. However the validity of each signal changes as follows de-pending on the mode of the teach pendant enable switch, the three modeswitch and the remote switch on the operator’s panel.

1.1.2Safety of the TeachPendant Operator


8

Operator panelthree mode switch

Teach pendantenable switch

Remotecondition

Teachpendant

Peripheraldevices

T1/T2/AUTO On Independent Allowed to start Not allowed

AUTO Off Local Not allowed Not allowed

AUTO Off Remote Not allowed Allowed to start

(6) When a program is completed, be sure to carry out a test run accordingto the procedure below.(a) Run the program for at least one operation cycle in the single step

mode at low speed.(b) Run the program for at least one operation cycle in the continuous

operation mode at low speed.(c) Run the program for one operation cycle in the continuous

operation mode at the intermediate speed and check that noabnormalities occur due to a delay in timing.

(d) Run the program for one operation cycle in the continuousoperation mode at the normal operating speed and check that thesystem operates automatically without trouble.

(e) After checking the completeness of the program through the testrun above, execute it in the automatic operation mode.

(7) While operating the system in the automatic operation mode, theteach pendant operator should leave the robot work area.


9

For the safety of maintenance personnel, pay utmost attention to thefollowing.

(1) Except when specifically necessary, turn off the power of thecontroller while carrying out maintenance. Lock the power switch,if necessary, so that no other person can turn it on.

(2) When disconnecting the pneumatic system, be sure to reduce thesupply pressure.

(3) Before the start of teaching, check that the robot and its peripheraldevices are all in the normal operating condition.

(4) If it is necessary to enter the robot work area for maintenance whenthe power is turned on, the worker should indicate that the machineis being serviced and make certain that no one starts the robotunexpectedly.

(5) Do not operate the robot in the automatic mode while anybody is inthe robot work area.

(6) When it is necessary to maintain the robot alongside a wall orinstrument, or when multiple workers are working nearby, makecertain that their escape path is not obstructed.

(7) When a tool is mounted on the robot, or when any moving deviceother than the robot is installed, such as belt conveyor, pay carefulattention to its motion.

(8) If necessary, have a worker who is familiar with the robot systemstand beside the operator panel and observe the work beingperformed. If any danger arises, the worker should be ready to pressthe EMERGENCY STOP button at any time.

(9) When replacing or reinstalling components, take care to preventforeign matter from entering the system.

(10)When handling each unit or printed circuit board in the controllerduring inspection, turn off the power of the controller and also turnoff the circuit breaker to protect against electric shock.

(11) When replacing parts, be sure to use those specified by FANUC.In particular, never use fuses or other parts of non-specified ratings.They may cause a fire or result in damage to the components in thecontroller.

1.1.3Safety DuringMaintenance


10

(1) Use a limit switch or other sensor to detect a dangerous condition and,if necessary, design the program to stop the robot when the sensorsignal is received.

(2) Design the program to stop the robot when an abnormal conditionoccurs in any other robots or peripheral devices, even though therobot itself is normal.

(3) For a system in which the robot and its peripheral devices are insynchronous motion, particular care must be taken in programmingso that they do not interfere with each other.

(4) Provide a suitable interface between the robot and its peripheraldevices so that the robot can detect the states of all devices in thesystem and can be stopped according to the states.

(1) Keep the component cells of the robot system clean, and operate therobot in an environment free of grease, water, and dust.

(2) Employ a limit switch or mechanical stopper to limit the robot motionso that the robot does not come into contact with its peripheral devicesor tools.

1.2SAFETY OF THETOOLS ANDPERIPHERALDEVICES

1.2.1Precautions inProgramming

1.2.2Precautions forMechanism


11

(1) When operating the robot in the jog mode, set it at an appropriatespeed so that the operator can manage the robot in any eventuality.

(2) Before pressing the jog key, be sure you know in advance whatmotion the robot will perform in the jog mode.

(1) When the work areas of robots overlap, make certain that the motionsof the robots do not interfere with each other.

(2) Be sure to specify the predetermined work origin in a motion programfor the robot and program the motion so that it starts from the originand terminates at the origin.Make it possible for the operator to easily distinguish at a glance thatthe robot motion has terminated.

(1) Keep the work area of the robot clean, and operate the robot in anenvironment free of grease, water, and dust.

1.3SAFETY OF THEROBOT MECHANISM

1.3.1Precautions inOperation


1.3.3Precautions forMechanisms


12

(1) To control the pneumatic, hydraulic and electric actuators, carefullyconsider the necessary time delay after issuing each control commandup to actual motion and ensure safe control.

(2) Provide the end effector with a limit switch, and control the robotsystem by monitoring the state of the end effector.

1.4SAFETY OF THE ENDEFFECTOR



13

(1) Never enter the robot work area while the robot is operating. Turn offthe power before entering the robot work area for inspection andmaintenance.

(2) If it is necessary to enter the robot work area with the power turnedon, first press the EMERGENCY STOP button on the operator panel.

(3) When replacing or reinstalling components, take care to preventforeign matter from entering the system.When replacing the parts in the pneumatic system, be sure to reducethe pressure in the piping to zero by turning the pressure control onthe air regulator.

(4) When handling each unit or printed circuit board in the controllerduring inspection, turn off the power of the controller and turn off thecircuit breaker to protect against electric shock.

(5) When replacing parts, be sure to use those specified by FANUC.In particular, never use fuses or other parts of non-specified ratings.They may cause a fire or result in damage to the components in thecontroller.

(6) Before restarting the robot, be sure to check that no one is in the robotwork area and that the robot and its peripheral devices are all in thenormal operating state.

1.5SAFETY INMAINTENANCE


14

Do not step on or climb the robot or controller as it may adversely affectthe robot or controller and you may get hurt if you lose your footing aswell.

(1) Step--on prohibitive label

Fig.1.6 (a) Step--on Prohibitive Label

Be cautious about a section where this label is affixed, as the sectiongenerates heat. If you have to inevitably touch such a section when it ishot, use a protective provision such as heat--resistant gloves.

(2) High--temperature warning label

Fig.1.6 (b) High--Temperature Warning Label

A high voltage is applied to the places where this label is attached.Before starting maintenance, turn the power to the control unit off, thenturn the circuit breaker off to avoid electric shock hazards. Be careful withservo amplifier and other units because high--voltage places in these unitsmay remain in the high--voltage state for a fixed time.

1.6WARNING LABELDescription

Description

Description


15

(3) High--voltage warning label

Fig.1.6 (c) High--Voltage Warning Label

There may be a high voltage in a place with this label. Before workingon such a portion, turn off the power to the controller and set its circuitbreaker to the off position to avoid shock hazards.In addition, be careful about servo amplifiers and other electric circuitsbecause a high voltage may remain in them for a certain period of timeafter the power is turned off.

Description

II MAINTENANCE

B--81525EN--1/01 1. OVERVIEWMAINTENANCE

19

1 OVERVIEW

This manual describes the maintenance and connection of the R--J3iBMate robot controller (called the R--J3iB Mate).

Maintenance Part : Troubleshooting, and the setting, adjustment,and replacement of units

Connection Part : Connection of the R--J3iB Mate controller to therobot mechanical unit and peripheral devices,and installation of the controller

WARNINGBefore you enter the robot working area, be sure to turn offthe power to the controller or press the EMERGENCYSTOP button on the operator panel or teach pendant.Otherwise, you could injure personnel or damageequipment.

TERMThe R--J3iB Mate robot controller uses the FANUC servoamplifier α i series (called the servo amplifier (i).The servo amplifier α i comprises a power supply module(PSM) and a servo amplifier module (SVM).In this manual, the terms “power supply module” and “servoamplifier module” refer to the individual modules. The term“servo amplifier” refers to the combination of the powersupply module and servo amplifier module.

2. CONFIGURATION B--81525EN--1/01MAINTENANCE

20

2 CONFIGURATION

B--81525EN--1/01 2. CONFIGURATIONMAINTENANCE

21

The appearance and components might slightly differ depending on thecontrolled robot, application, and options used.Fig.2.1 (a) shows the view of R--J3iB Mate.Fig.2.1 (b) shows the R--J3iB Mate consists of the R--J3iB Mate controller.

Teach pendant

Operatorpanel

R--J3iB Mate controller

Teach pendantcable

Fan unit

ON/OFF handle

Fig.2.1 (a) External View of the R--J3iB Mate Controller

2.1EXTERNAL VIEW OFTHE CONTROLLER


22

Robot controller P.C. boardOption slot

Back plane

Servo amplifier module2 (AMP2)Servo amplifier module1 (AMP1)

Power supply module (PSM)AC reactle

Teach pendantEnable/disable switch Emergency stop

button

Power supply transformerfor brake

Power supply unitEmergency stop unit

Emergency stop P.C.board

Heat exchangeEmergency stopbutton

Mode switch

Fig.2.1 (b) R--J3iB Mate interior (Front)

Circut protector(on/off switch) Noise filter

Circuit protector

MCC

Transformer

Fig.2.1 (c) R--J3iB Mate interior (Side)


23

Table 2.1 Servo amplifier specifications

Robot Power supply module Servo amplifier module1 Servo amplifier module2

LR Mate 100iB

A06B--6115--H001(αPSMR--1i)

A06B--6114--H205(αSVM--20/20i)

A06B--6114--H302(αSVM--10/10/10i)

LR Mate 100iB L M L M NJ1 J2 J3 J4 J5

LR Mate 200iB

A06B--6115--H001(αPSMR--1i)

A06B--6114--H302(αSVM--10/10/10i)

A06B--6114--H302(αSVM--10/10/10i)

LR Mate 200iB L M N L M NJ1 J2 J3 J4 J5 J6


24

-- Robot control printed circuit boardThis board is equipped with a microprocessor and its peripheralcircuitry, memory, and operator panel control circuit. A servo controlcircuit is also included.

-- Emergency stop unit, emergency stop printed circuit boardThis unit controls the emergency stop system, magnetic contactor(MCC) of the servo amplifier, and brake. The unit contains the powersupply unit for converting the AC power to the DC power.

-- Backplane printed circuit board

Various control boards are mounted on the backplane PC board.-- Teach pendant

This unit is used to carry out all operations including robotprogramming. The liquid crystal display (LCD) of this unit displaysthe status of the control unit, data, and the like.

-- Servo amplifierThe servo amplifier amplifies the power of the servo amplifier andcontrols the pulse coder.

-- MCCThe MCC controls the main power of the servo amplifier.

-- Operator panelThe operator panel has a port for the serial interface to an externaldevice. The panel also has an EMERGENCY STOP button.

-- TransformerThe transformer converts the input power into the AC voltagerequired for the control unit.

-- Fan unit, heat exchangerThese components are used to cool the inside of the control unit.

-- Circuit protectorThis component turns on or off the power.The input power is connected to the circuit protector in order toprotect the equipment from a large current that could result from aproblem in the electric system of the control unit or an abnormal inputpower.

2.2COMPONENTFUNCTIONS


25

Daily maintenance and periodic maintenance/inspection ensure reliablerobot performance for extended periods of time.

(1) Daily maintenanceBefore operating the system each day, clean each part of the systemand check the system parts for any damage or cracks. Also check thefollowing:(a) Before service operation

Check the cable connected to the teach pendant for excessivetwisting. Check the controller and peripheral devices forabnormalities.

(b) After service operationAt the end of service operation, return the robot to the specifiedposition, then turn off the controller. Clean each part, and checkfor any damage or cracks. If the ventilation port of the controlleris dusty, clean it.

(c) Check after one monthCheck that the fan is rotating normally. If the fan has dirt and dustbuilt up, clean the fan according to step (d) described below forinspection to be performed every 6 months.

(d) Periodic inspection performed every six monthsRemove the top cover, louver, and back panel (if possible), thenremove any dirt and dust from the inside of the transformercompartment. Wipe off dirt and dust from the fan andtransformer.

(2) Maintenance toolsThe following maintenance tools are recommended:(a) Measuring instruments

AC/DC voltmeter (A digital voltmeter is sometimes required.)Oscilloscope with a frequency range of 5 MHz or higher, twochannels

(b) ToolsPhillips screwdrivers : Large, medium, and smallStandard screwdrivers: Large, medium, and smallNut driver set (Metric)PliersNeedle-nose pliersDiagonal cutting pliers

2.3PREVENTIVEMAINTENANCE

3. TROUBLESHOOTING B--81525EN--1/01MAINTENANCE

26

3 TROUBLESHOOTING

This chapter describes the checking method and corrective action for eacherror code indicated if a hardware alarm occurs. Refer to the operator’smanual to release program alarms.

B--81525EN--1/01 3. TROUBLESHOOTINGMAINTENANCE

27

Check and Corrective action Figure

(Check 1) Check that the circuit protector is on andhas not tripped.

Circuit protector(Correctiveaction)

Turn on the circuit protector.Circuit protector(on/off switch)

(Check 2) Check that the door fan unit and the fanmotor of the heat exchanger are rotatingand that the LED indication on the powersupply module is “--”.

Heat exchange forfan unit (door face)

LED of the power supply module

(Correctiveaction)

If the fan motor is not rotating or if theLED of the power supply module is notglowing, the fuse on the back of the doormay have been blown.-- Check the fuse on the back of the

door.If the fuse on the back of the door hasbeen blown, replace the fuse.

Circuit protector

Transformer unit

3.1POWER CANNOT BETURNED ON


28


(Check 1) Check the LCD display and LED indica-tion on the teach pendant. Teach pendant

(Correctiveaction)

Check the LCD display and LED indica-tion on the teach pendant to see whetherthe emergency stop unit is faulty.-- Check whether the fuse FUS4 on the

emergency stop PC board is blown.If the fuse is blown, the FALM LEDglows. Replace the blown fuse.

-- If the fuse FUS4 on the emergencystop PC board is not blown, the emer-gency stop unit may be faulty. Re-place the emergency stop unit.

p


Fuse FUS4

FALM LED

Emergency stop unit

3.1.1Teach Pendant Cannotbe Turned On


29


(Check 1) Check that the “.” portion of the seven--segment LED glows on the robot control-ler PC board.

(Correctiveaction)

If the “.” portion is not glowing, the fuseFUS1 on the robot controller PC boardmay be blown. Alternatively, the DC/DCconverter module may be damaged.If the FUSE ALARM LED is glowing, thefuse FUS1 may be blown.The fuse FUS1 is provided on the robotcontroller PC board. Before checkingthe fuse, turn off the circuit protector.a) If the fuse FUS1 has been blown-- See Corrective action (1).b) If the fuse FUS1 is not blown-- See Corrective action (2).

+24V inputconnectorCP5

(Correctiveaction(1))

Cause of the blowing of the fuse FUS1and corrective actiona) Check whether the device which is

connected to the RS--232--C/RS--422 port and requires the powersupply of +24 V is sound.

b) Problem in the DC/DC convertermoduleIf the DC/DC converter module getsfaulty in the short--circuit mode,FUS1 is blown.Replace the DC/DC converter mod-ule.

DC/DC convertermodule

dot part of sevensegment LED

(Correctiveaction(2)) a) Problem in the DC/DC converter

moduleReplace the DC/DC converter mod-ule.

b) Problem in the robot controller PCboardReplace the robot controller PCboard. (For the LED indications, seeSection 3.7, “TROUBLESHOOTINGUSING LEDS.”)

FUS1 7.5ADC24V input fuse

3.1.2Initial Screen Remainson the Teach Pendant


30

The alarm occurrence screen displays only the alarm conditions that arecurrently active. If an alarm reset signal is input to reset the alarmconditions, the alarm occurrence screen displays the message “PAUSE ormore serious alarm has not occurred.”

The alarm occurrence screen displays only the alarm conditions (if any)that occur after the most recently entered alarm reset signal. To erase allalarm displays from the alarm occurrence screen. Press the CLEAR key(+ shift) on the alarm history screen.The alarm occurrence screen is intended to display PAUSE or moreserious alarms. It will not display WARN, NONE, or a reset. It is possibleto disable PAUSE and some of more serious alarms from being displayedby setting the $ER_NOHIS system variable appropriately.If two or more alarms have occurred, the display begins with the mostrecent alarm.Up to 100 lines can be displayed.If an alarm has a cause code, it is displayed below the line indicating thealarm.

Press the screenselection key to select[4 ALARM]. Press the alarm key.

Automatic alarm displayupon occurrence

Alarm occurrence screen display

Press F3 [ACTIVE]. Press F3 [HIST].

Alarm history screen display

Fig.3.2 Alarm Occurrence Screen and Alarm History Screen DisplayProcedure

3.2ALARMOCCURRENCESCREEN


31

Displaying the alarm history/alarm detail information

(1) Press the MENUS key to display the screen menu.

(2) Select [ALARM].You will see a screen similar to the following

MENUS

34 ALARM5 I/O

INTP-224 (SAMPLE1, 7) Jump label is failMEMO-027 Specified line does not existAlarm JOINT 30 %

1/251 INTP-224 (SAMPLE1, 7) Jump label is2 SRVO-002 Teach pendant E-stop3 R E S E T4 SRVO-027 Robot not mastered(Group:1)5 SYST-026 System normal power up

[ TYPE ] CLEAR HELP

NOTEThe latest alarm is assigned number 1. To view messagesthat are currently not on the screen, press the F5, HELP,then press the right arrow key.

(3) To display the alarm detail screen, press F5, [HELP].

CLEAR HELP

F5

INTP-224 (SAMPLE1, 7) Jump label is fail

INTP-224 (SAMPLE1, 7) Jump label is failMEMO-027 Specified line does not exist30-MAY-44 07:15STOP.L 00000110Alarm

1/251 INTP-224 (SAMPLE1, 7) Jump label is2 SRVO-002 Teach pendant E-stop

[ TYPE ] CLEAR HELP

(4) To return to the alarm history screen, press the PREV key.

PREV

(5) To delete all the alarm histories, press and hold down the SHIFT key,then press F4, [CLEAR].

NOTEWhen system variable $ER_NOHIS = 1, NONE alarms orWARN alarms are not recorded. When $ER_NOHIS=2,resets are not recorded in the alarm history. When$ER_NOHIS=3, resets, WARN alarms, and NONE alarmsare not recorded.

CLEAR HELP

F4SHIFT

Step


32

The following map indicates teach pendant operations used to check analarm.

4 ALARM

F1 [TYPE]

Alarm : Active

F1 [TYPE]

F3 HIST

Alarm : HIST

F1 [TYPE]

F3 [ACTIVE]

F4 CLEAR

F5 HELP

DETAIL Alarm

F1 [TYPE]

F3 [ACTIVE]

F4 CLEAR

F5 HELP


33

The safety signal screen indicates the state of signals related to safety. Tobe specific, the screen indicates whether each safety signal is currently on.On this screen, it is impossible to change the state of any safety signal.

Table 3.3 Safety Signals

Safety signal Description

Operator panel emergency stop This item indicates the state of the emergency stop button on the operator panel. If theEMERGENCY STOP board is pressed, the state is indicated as “TRUE”.

Teach pendant emergency stop This item indicates the state of the emergency stop button on the teach pendant. If theEMERGENCY STOP board is pressed, the state is indicated as “TRUE”.

External emergency stop This item indicates the state of the external emergency stop signal. If the EMERGENCYSTOP signal is input, the state is indicated as “TRUE”.

Fence open This item indicates the state of the safety fence. If the safety fence is open, the state isindicated as “TRUE”.

Deadman switch This item indicates whether the DEADMAN switch on the teach pendant is grasped. Ifthe teach pendant is operable, and the DEADMAN switch is grasped, the state is indi-cated as “TRUE”. If the deadman switch is released when the teach pendant is operable,an alarm occurs, causing the servo power to be switched off.

Teach pendant operable This item indicates whether the teach pendant is operable. If the teach pendant is oper-able, the state is indicated as “TRUE”.

Hand broken This item indicates the state of the hand safety joint. If the hand interferes with a work-piece or anything like this, and the safety joint is opened, the state is indicated as“TRUE”. In this case, an alarm occurs, causing the servo power to be switched off.

Robot overtravel This item indicates whether the current position of the robot is out of the operation range.If any robot articulation goes out of the operation range beyond the overtravel switch, thestate is indicated as “TRUE”. In this case, an alarm occurs, causing the servo power to beswitched off.

Abnormal air pressure This item indicates the state of the air pressure. The abnormal air pressure signal is con-nected to the air pressure sensor. If the air pressure is not higher than the specifiedvalue, the state is indicated as “TRUE”.

(1) Press the MENUS key to display the screen menu.

(2) Select STATUS on the next page.

(3) Press F1, [TYPE] to display the screen switching menu.

(4) Select Safety Signal. You will see a screen similar to the following.

SYSTEM Safety JOINT 30%

SIGNAL NAME STATUS 1/11

1 SOP E-Stop: FALSE2 TP E-stop: FALSE3 Ext E-Stop: FALSE4 Fence Open: FALSE5 TP Deadman: TRUE6 TP Enable: TRUE7 Hand Broken: FALSE8 Over Travel: FALSE9 Low Air Alarm: FALSE

[TYPE]

3.3SAFETY SIGNALS

Step


34

Mastering is needed if:

(1) The SRVO 062 BZAL or SRVO 038 pulse mismatch alarm occurs,or

(2) The pulse coder is replaced.

Item (1) requires simplified mastering, while item (2) requireszero--degree or jig position mastering. (Zero--degree position masteringis just for quick--fix purposes. After zero--degree position mastering isused, jig position mastering should be performed later.)The mastering procedure is described below. For details, refer to anapplicable maintenance manual of mechanical unit or operator’s manualof control unit.

System variable $MASTER_ENB must be set to 1 or 2.

SYSTEM Variables JOINT 10%57/136

57 $MASTER_ENB 1

(1) Press <MENUS>.

(2) Select SYSTEM.

(3) Press F1, TYPE.

(4) Select Master/Cal you will see a screen similar to the following.

F1

Master/Cal

TYPE

SYSTEM Master/Cal JOINT 30%

1 FIXTURE POSITION MASTER

2 ZERO POSITION MASTER3 QUICK MASTER4 SINGLE AXIS MASTER5 SET QUICK MASTER REF6 CALIBRATE

Press ’ENTER’ or number key to select.

[TYPE] LOAD RES_PCA DONE

5 POSITION6 SYSTEM7

MENUS

9 USER0 -- NEXT --

(5) Move the robot by jog feed to the mastering position. Release thebrake on the manual brake control screen if necessary.

NOTEMastering can not be performed until the axis is rotatedenough to establish a pulse.

3.4MASTERING

Condition

Step


35

(6) Select “1 FIXTURE POSITION MASTER” and press the F4 key(yes). Mastering data is set.

F4

SYSTEM Master/Cal

1 FIXTURE POSITION MASTER2 ZERO POSITION MASTERMaster at master position? [NO]

ENTER

Master at master position? [NO][ TYPE ] YES NO

SYSTEM Master/Cal JOINT 30 %

1 FIXTURE POSITION MASTER2 ZERO POSITION MASTER3 QUICK MASTER4 SINGLE AXIS MASTER5 SET QUICK MASTER REF6 CALIBRATE

Robot Mastered! Mastering Data:<0> <11808249> <38767856><9873638> <122000309> <2000319>

[ TYPE ] LOAD RES_PCA DONE

(7) Select “6 CALIBRATE” and press the F4 key (yes). Calibration isperformed.Alternatively, to perform positioning, turn the power off, then turn iton again. Calibration is performed whenever the power is turned on.

F4

5 SET QUICK MASTER REF6 CALIBRATECalibrate? [NO] ENTER

Calibrate? [NO][ TYPE ] YES NO

SYSTEM Master/Cal JOINT 30 %

1 FIXTURE POSITION MASTER2 ZERO POSITION MASTER3 QUICK MASTER4 SINGLE AXIS MASTER5 SET QUICK MASTER REF6 CALIBRATE

Robot Calibrated! Cur Jnt Ang(deg):<10.000> <-25.000> <40.000><5.000> <-15.000> <0.000>

[ TYPE ] LOAD RES_PCA DONE

(8) Press F5 “DONE”, after mastering.

F5

DONE


36

(1) SRVO--001 SVAL1 Operator panel E--stop(Explanation) The EMERGENCY STOP button on the operator

panel is pressed.(Action 1) Release the emergency stop button pressed on the

operator panel.(Action 2) Release the EMERGENCY STOP button on the

operator panel.(Action 3) Replace the emergency stop unit.

Before taking (Action 4), make a backup copy of allthe programs and settings of the control unit.

(Action 4) Replace the robot controller PC board.

Emergency stop button

Emergency stop unit

Robot controller P.C. board

Operatorpanel

Fig.3.5 (1) (a) SRVO--001 SVAL1 Operator panel E--stop

3.5TROUBLESHOOTINGUSING THE ERRORCODE


37

(2) SRVO--002 SVAL1 Teach pendant E--stop(Explanation) The emergency stop button on the operator’s Teach

Pendant was pressed.(Action 1) Release the emergency stop button on the teach

pendant.(Action 2) Replace Teach Pendant.

Emergency stop button

Fig.3.5 (2) SRVO--002 SVAL1 Teach pendant E--stop

(3) SRVO--003 SVAL1 Deadman switch released(Explanation) The teach pendant is enabled, but the deadman switch

is not pressed.(Action 1) Press the deadman switch to run the robot.(Action 2) Replace the teach pendant.

Deadman switch

Fig.3.5 (3) SRVO--001 SVAL1 Deadman switch released


38

(4) SRVO--004 SVAL1 Fence open(Explanation) In AUTO mode, there is no short circuit between

FENCE1 and FENCE2 on the terminal block TBEB5of the emergency stop PC board.If the safety fence is connected between FENCE1 andFENCE2, the door of the safety fence is open.

(Action 1) When the safety fence is connected, close the door.(Action 2) Check the cables and switches connected to FENCE1

and FENCE2.(Action 3) When this signal is not used, short--circuit between

FENCE1 and FENCE2.

NOTEIn the system that uses the fence signal, do not short--circuitthis signal to disable it because the operation is dangerous.When this signal must be temporarily short--circuited, makesafety provisions separately.

(Action 4) When AUTO mode is not entered even though themode switch is set to AUTO, the mode switch may befaulty. Replace the operator panel.

(Action 5) Replace the teach pendant cable.(Action 6) Replace the teach pendant.(Action 7) Replace the emergency stop unit.

Before taking (Action 8), make a backup copy of allthe programs and settings of the control unit.


Emergency stop unit

Shortconnectionboard

Fig.3.5 (4) SRVO--004 SVAL1 Fence open


39

(5) SRVO--005 SVAL1 Robot overtravel(Explanation) This alarm should not occur because no overtravel

input signal is provided. However, this alarm can becaused by an abnormal overtravel input signal acrossthe robot interconnection cable and robot controllerPC board.

(Action 1) Check the robot interconnection cable (RMP) for thefollowing.1) The male and female connection pins are not

twisted or are not loose.2) The connector is securely connected.3) The cable is free from a break and ground fault.Next, check that the connector CRM82 of the robotcontroller PC board is securely connected. Inaddition, check that the RMP cable is sound and freefrom a break or visible twist.Before taking (Action 2), make a backup copy of allthe programs and settings of the control unit.



Fig.3.5 (5) SRVO--005 SVAL1 Robot overtravel


40

(6) SRVO--006 SVAL1 Hand broken(Explanation) The safety joint, if any, is broken. If no joint is

broken, the HBK signal line of the robotinterconnection cable has a break or ground fault.

(Action 1) Holding down the shift key, press the alarm releasebutton. This releases the alarm. Keeping on holdingdown the shift key, carry out jog feed to move the toolto the work area.1) Replace the safety joint.2) Examine the cable.

(Action 2) Check the robot interconnection cable (RMP) for thefollowing.1) The male and female connection pins are not

twisted or are not loose.2) The connector is securely connected.3) The cable is free from a break and ground fault.Next, check that the connector CRM82 of the robotcontroller PC board is securely connected. Inaddition, check that the RMP cable is sound and freefrom a break or visible twist.Before taking (Action 3), make a backup copy of allthe programs and settings of the control unit.



Fig.3.5 (6) SRVO--006 SVAL1 Hand broken


41

(7) SRVO--007 SVAL1 External E--stop(Explanation) EMGIN1 and EMGIN2 on the terminal blockTBEB5

of the emergency stop PC board are notshort--circuited. If an external emergency stop switchis connected across EMGIN1 and EMGIN2, theswitch has been pressed.

(Action 1) If an external emergency stop switch is connected,releases the switch.

(Action 2) Check the switch and cable connected to EMGIN1and EMGIN2.

(Action 3) When this signal is not used, make a connectionbetween EMGIN1 and EMGIN2. (WARNING)

(Action 4) Replace the emergency stop unit.

WARNINGDo NOT short--circuit, or disable, this signal in a system inwhich the External emergency stop input signal is in use, asit is very dangerous. If it is necessary to run the robot byshort--circuiting the signal even temporarily, an additionalsafety provision must be provided.

Emergency stop unit


Fig.3.5 (7) SRVO--007 SVAL1 External E--stop


42

(8) SRVO--009 SVAL1 Pneumatic pressure alarm(Explanation) An abnormal air pressure was detected. The input

signal is located on the end effector of the robot.Refer to the manual of your robot.

(Action 1) If an abnormal air pressure is detected, check the cause.If the peripheral device are normal, check the robotconnection cable.Before taking (Action 2), make a backup copy of allthe programs and settings of the control unit.



Fig.3.5 (8) SRVO--009 SVAL1 Pneumatic pressure alarm


43

(9) SRVO--014 WARN Fan motor abnormal(Explanation) A fan motor in the backplane unit is abnormal.(Action) Check the fan motor and its cables. Replace them if

necessary.

Fan motor

Fig.3.5 (9) SRVO--014 WARN Fan motor abnormal


44

(10)SRVO--015 SVAL1 SYSTEM OVER HEAT (Group : i Axis : j)(Explanation) The temperature in the control unit exceeds the

specified value.(Action 1) If the ambient temperature is higher than specified

(45°C), cool down ambient temperature.(Action 2) If the fan motor is not running, check it and its cables.

Replace them if necessary.(Action 3) If the thermostat on the robot controller PC board is

defective, replace the robot controller PC board.

Fan motor(on the heat exchange)

Fan motor (door face) Robot controller P.C. board

Fig.3.5 (10) SRVO--015 SVAL1 SYSTEM OVER HEAT


45

(11) SRVO--021 SVAL1 SRDY off (Group : i Axis : j)(Explanation) The HRDY is on and the SRDY is off, although there

is no other cause of an alarm. (HRDY is a signal withwhich the host directs the servo system whether toturn on or off the servo amplifier magnetic contactor.SRDY is a signal with which the servo systeminforms the host whether the magnetic contactor isturned on.)If the servo amplifier magnetic contactor cannot beturned on when directed so, it is most likely that aservo amplifier alarm has occurred. If a servoamplifier alarm has been detected, the host will notissue this alarm (SRDY off). Therefore, this alarmindicates that the magnetic contactor cannot be turnedon for an unknown reason.

(Action 1) Measure the voltage of the 200--VAC input to thepower supply module. If the voltage is 170 VAC orlower, adjust the input voltage.

(Action 2) Check that CRR78 of the emergency stop PC boardand CX3 and CX4 of the power supply module aresecurely connected. Check the cables of theemergency stop PC board and power supply modulefor a break.

(Action 3) Check the EMERGENCY STOP line (teach pendantemergency stop, teach pendant enable/disable switch,teach pendant deadman switch, operator panelemergency stop, external emergency stop input, fenceinput, servo off--input) for a possibility of aninstantaneous interruption. If the software cannotjudge the cause of the alarm at an instantaneousinterruption of the EMERGENCY STOP line, thisalarm occurs.

(Action 4) Replace the emergency stop unit.(Action 5) If an alarm occurs on all axes, the power supply

module may be faulty. Replace the power supplymodule.

(Action 6) If an alarm occurs on a particular axis, the servoamplifier module may be faulty. Replace the servoamplifier module controlling the axis.

(Action 7) Replace the axis control card on the robot controllerPC board.


46

Robot controller P.C. boardServo amplifier module

Power supply module

Emergency stop unit

Axis control card

Fig.3.5 (11) SRVO--021 SVAL1 SRDY off


47

(12)SRVO--022 SVAL1 SRDY on (Group : i Axis : j)(Explanation) When the HRDY is about to go on, the SRDY is already

on. (HRDY is a signal with which the host directs theservo system whether to turn on or off the servoamplifier magnetic contactor. SRDY is a signal withwhich the servo system informs the host whether themagnetic contactor is turned on.


(Action 2) If an alarm occurs on all axes, the power supplymodule may be faulty. Replace the power supplymodule.

(Action 3) If an alarm occurs on a particular axis, the servoamplifier module may be faulty. Replace the servoamplifier module controlling the axis.


Power supply moduleAxis control card

Fig.3.5 (12) SRVO--022 SVAL1 SRDY on


48

(13)SRVO--023 SVAL1 Stop error excess (Group : i Axis : j)(Explanation) When the servo is at stop, the position error is

abnormally large.(Action 1) Check whether the motor brake has been released.(Action 2) Make sure that the servo amplifier CZ2L to N are

connected tightly.(Action 3) Check to see if the load is greater than the rating. If

greater, reduce it to within the rating. (If the load istoo greater, the torque required for acceleration /deceleration becomes higher than the capacity of themotor. As a result, the motor becomes unable tofollow the command, and an alarm is issued.)

(Action 4) Check each phase voltage of the CZ1 connector of thethree--phase power (200 VAC) input to the servoamplifier. If it is 170 VAC or lower, check the linevoltage. (If the voltage input to the servo amplifierbecomes low, the torque output also becomes low. Asa result the motor may become unable to follow thecommand, hence possibly an alarm.)

(Action 5) If the line voltage is 170 VAC or higher, replace thepower supply module or servo amplifier module.

(Action 6) Check disconnection of robot connection cable(RMP).

(Action 7) Replace the motor.

Servo amplifier modulePower supply module

Fig.3.5 (13) SRVO--023 SVAL1 Stop error excess


49

(14)SRVO--024 SVAL1 Move error excess (Group : i Axis : j)(Explanation) When the robot is running, its position error is greater

than a specified value ($PARAM _ GROUP.$MOVER _ OFFST or $PARAM _ GROUP.$TRKERRLIM). It is likely that the robot cannotfollow the speed specified by program.

(Action 1) Check the robot for binding axis.(Action 2) Take the same actions as described for the above

alarm.(15)SRVO--025 SVAL1 Motn dt overflow (Group : i Axis : j)

(Explanation) The specified value is too great.(16)SRVO--026 WARN2 Motor speed limit (Group : i Axis : j)

(Explanation) A value higher than the maximum motor speed($PARAM_GROUP.$MOT_SPD_LIM) wasspecified. The actual motor speed is clamped to themaximum speed.

(17)SRVO--027 WARN Robot not mastered (Group : i)(Explanation) An attempt was made to calibrate the robot, but the

necessary adjustment had not been completed.(Action) Master the robot.

(18)SRVO--030 SVAL1 Brake on hold (Group : i)(Explanation) This alarm occurs when the robot pauses, if the brake

on hold function has been enabled ($SCR.$BRKHOLD _ ENB = 1). Disable the function if it isnot necessary.

(Action) Disable [Servo--off during pause] on the generalsetting menu (Select Setting general).

(19)SRVO--031 SVAL1 User servo alarm (Group : i)(Explanation) An user servo alarm occurred.

(20)SRVO--033 WARN Robot not calibrated (Group : i)(Explanation) An attempt was made to set up a reference point for

simplified adjustment, but the robot had not beencalibrated.

(Action) Calibrate the robot.1.Supply power.2.Set up a simplified adjustment reference point

using [Positioning] on the positioning menu.(21)SRVO--034 WARN Ref pos not set (Group : i)

(Explanation) An attempt was made to perform simplifiedadjustment,but the reference point had not been set up.

(Action) Set up a simplified adjustment reference point on thepositioning menu.

(22)SRVO--035 WARN2 Joint speed limit (Group : i Axis : j)(Explanation) A value higher than the maximum axis speed

($PARAM_GROUP.$JNTVELLIM) was specified.Each actual axis speed is clamped to the maximumspeed.

(23)SRVO--036 SVAL1 Inpos time over (Group : i Axis : j)(Explanation) The robot did not get to the effective area ($PARAM _

GROUP.$ STOPTOL) even after the position checkmonitoring time ($PARAM _ GROUP. $INPOS _TIME) elapsed.

(Action) Take the same actions as for SRVO--23 (large positionerror at a stop).

(24)SRVO--037 SVAL1 Imstp input (Group : i)(Explanation) The *IMSTP signal for a peripheral device interface

was input.(Action) Turn on the *IMSTP signal.


50

(25)SRVO--038 SVAL2 Pulse mismatch (Group : i Axis : j)(Explanation) The pulse count obtained when power is turned off

does not match the pulse count obtained when poweris applied. This alarm is asserted after exchange thepulsecoder or battery for back up of the pulsecoderdata or loading back up data to the Robot controllerPC board.

(Action) Perform Absolute Pulse Coder reset and remasterrobot (RES--PCA)1. Press MENUS.2. Select SYSTEM.3. Press F1 [TYPE].4. Select MASTER/CAL.5. Press F3, PES--PCA and YES.6. Execute machining.7. Press RESET.

The fault condition should reset. If the controlleris still faulted with additional servo--relatederrors,cold start the controller.It might be necessary to remaster the robot.

(26)SRVO--041 SVAL2 MOFAL alarm (Group : i Axis : j)(Explanation) The servo value was too high.(Action) Cold start the controller.


51

(27)SRVO--044 SVAL1 HVAL alarm (Group : i Axis : j)(Explanation) The DC voltage (DC link voltage) of the main circuit

power supply is abnormally high.The LED indication on the power supply module is“7” (HVAL).

(Action 1) Check the three--phase input voltage at the powersupply module. If it is 253 VAC or higher, check theline voltage. (If the three--phase input voltage ishigher than 253 VAC, high acceleration/decelerationcan result in this alarm.)

(Action 2) Check that the load weight is within the rating. If itis higher than the rating, reduce it to within the rating.(If the machine load is higher than the rating, theaccumulation of regenerative energy might result inthe HVAL alarm even when the three--phase inputvoltage is within the rating.

(Action 3) Replace the power supply module.

Power supply module

Fig.3.5 (27) SRVO--044 SVAL1 HVAL alarm


52

(28)SRVO--045 SVAL1 HCAL alarm (Group : i Axis : j)(Explanation) Abnormally high current flowed in the main circuit of

the servo amplifier module.The LED indications on the servo amplifier modulesare “b”, “C”, and “d”.

(Action 1) Disconnect the Robot connection cable (Motor power)from the connector CZ2 of the servo amplifiermodule. If error occurs, replace the servo amplifier.

(Action 2) Disconnect the Robot connection cable (Motor power)from the servo amplifier module connector (CZ2),and check the insulation of each Robot connectioncable (Motor power) (U, V, or W) and the GND line.If there is a short--circuit, the motor, robotinterconnection cable, or intra--robot cable isdefective. Check them and replace them if necessary.

(Action 3) Disconnect the Robot connection cable (Motor power)from the servo amplifier module connector (CZ2),and measure the resistance between the U and V, Vand W, and W and U with a ohmmeter with a very lowresistance range. If the resistances at these threeplaces are different from each other, the motor, robotinterconnection cable, or intra--robot cable isdefective. Check each item in detail.Before taking (Action 4), make a backup copy of allthe programs and settings of the control unit.



Fig.3.5 (28) SRVO--045 SVAL1 HCAL alarm


53

(29)SRVO--046 SVAL2 OVC alarm (Group : i Axis : j)(Explanation) This alarm is issued to prevent the motor from

thermal damage that might occur when the root meantsquare current calculated within the servo system isout of the allowable range.

(Action 1) Check the operating conditions for the robot and relaxthe service conditions.

(Action 2) Check each phase voltage of the three--phase inputpower (200 VAC for the power supply module. If itis 170 VAC or lower, check the line voltage.

(Action 3) Replace the power supply module and servoamplifier module.

(Action 4) Check the robot connection cable (RMP).(Action 5) Replace the motor.


Fig.3.5 (29) SRVO--046 SVAL2 OVC alarm


54

Relationships among the OVC, OVL, and HC alarmsOverviewThis section points out the differences among the OVC, OVL, and HCalarms and describes the purpose of each alarm.Alarm detection section

Abbreviation Designation Detection section

OVC Overcurrent alarm Servo software

OVL Overload alarm Thermal relay in the motor OHAL2Thermal relay in the servo amplifier OHAL1Thermal relay in the separate regenerative dis-charge unit DCAL

HC High current alarm Servo amplifier

Purpose of each alarm1) HC alarm (high current alarm)

If high current flow in a power transistor momentarily due toabnormality or noise in the control circuit, the power transistor andrectifier diodes might be damaged, or the magnet of the motor mightbe degaussed. The HC alarm is intended to prevent such failures.

2) OVC and OVL alarms (overcurrent and overload alarms)The OVC and OVL alarms are intended to prevent overheat that maylead to the burnout of the motor winding, the breakdown of the servoamplifier transistor, and the separate regenerative resistor.The OVL alarm occurs when each built--in thermal relay detects atemperature higher than the rated value. However, this method is notnecessarily perfect to prevent these failures. For example, if themotor frequently repeats to start and stop, the thermal time constantof the motor, which has a large mass, becomes higher than the timeconstant of the thermal relay, because these two components aredifferent in material, structure, and dimension. Therefore, if themotor repeats to start and stop within a short time as shown in Fig.1, the temperature rise in the motor is steeper than that in the thermalrelay, thus causing the motor to burn before the thermal relay detectsan abnormally high temperature.

Temperature

Start StartStartStop Stop

Temperature atwhich the windingstarts to burn

Thermal time constantof the motor is high.

Thermal time constantof the thermal relay islow.

Time

Fig.1 Relationship between the temperatures of the motor and thermal relay on start/stop cycles

To prevent the above defects, software is used to monitor the currentin the motor constantly in order to estimate the temperature of themotor. The OVC alarm is issued based on this estimated temperature.This method estimates the motor temperature with substantialaccuracy, so it can prevent the failures described above.

Reference


55

To sum up, a double protection method is used; the OVCalarm isusedfor protection from a short--time overcurrent, and the OVL alarm isused for protection from long--term overload. The relationshipbetween the OVC and OVL alarms is shown in Fig 2.

CurrentProtection area forthe motor andservo amplifier

Protection by the OVLLimit current

Protection bythe OVC

Rated continuous current

Time

Fig.2 Relationship between the OVC and OVL alarms

NOTEThe relationship shown in Fig. 2 is taken into considerationfor the OVC alarm. The motor might not be hot even if theOVC alarm has occurred. In this case, do not change theparameters to relax protection.

(30)SRVO--047 SVAL1 LVAL alarm (Group : i Axis : j)(Explanation) The control power voltage (+5 V, etc.) on the servo

amplifier module is too low. The LED indication onthe servo amplifier module is “2” (LVAL).

(Action 1) Replace the servo amplifier module.

Servo amplifier module

Fig.3.5 (30) SRVO--047 SVAL1 LVAL alarm


56

(31)SRVO--049 SVAL1 OHAL1 alarm (Group : i Axis : j)(Explanation) This alarm does not occur when the power supply

module and serve amplifier modules used with theR--J3iB Mate are under normal conditions.This alarm indicates that any of the power supplymodule and servo amplifier modules is faulty.

(Action 1) If this alarm occurs in relation to all axes, replace thepower supply module.

(Action 2) If this alarm occurs in relation to a specific axis,replace the servo amplifier module that controls theaxis.


Fig.3.5 (31) SRVO--049 SVAL1 OHAL1 alarm


57

(32)SRVO--050 SVAL1 CLALM alarm (Group : i Axis : j)(Explanation) The disturbance torque estimated by the servo software

is abnormally high. (A collision has been detected.)(Action 1) Check that the robot has collided with anything. If it

has, reset the robot and jog--feed it to recover from thecollision.

(Action 2) Make sure that the load setting is correct.(Action 3) Check that the load weight is within the rating. If it

is higher than the rating, reduce it to within the rating.(If the robot is used out of its usable range, theestimated disturbance torque becomes abnormallyhigh, possibly resulting in this alarm being detected.)

(Action 4) Check the phase voltage of the three--phase inputpower (200 VAC) to the power supply module. If itis 170 VAC or lower, check the line voltage.

(Action 5) Replace the power supply module and the servoamplifier module.


Fig.3.5 (32) SRVO--050 SVAL1 CLALM alarm


58

(33)SRVO--051 SVAL2 CUER alarm (Group : i Axis : j)(Explanation) The offset of the current feedback value is abnormally

high.(Action) Replace the servo amplifier module.


Fig.3.5 (33) SRVO--051 SVAL2 CUER alarm


59

(34)SRVO--054 DSM Memory Error(Explanation) An access to the axis control card on the robot

controller PC board memory fails.(Action) Replace the axis control card.


Axis control card

Fig.3.5 (34) SRVO--054 DSM Memory Error


60

(35)SRVO--055 SVAL2 FSSB com error 1 (Group : i Axis : j)(Explanation) A communication error has occurred between the

robot controller PC board and servo amplifier.(Action 1) Check the communication cable (optical fiber)

between the robot controller PC board and servoamplifier. Replace it if it is faulty.


(Action 3) Replace the servo amplifier module.Before continuing to the next step, perform acomplete controller back--up to save all yourprograms and settings. Failure to perform this couldresult in damage to equipment or lost data.



Axis control card

Fig.3.5 (35) SRVO--055 SVAL2 FSSB com error 1


61

(36)SRVO--056 SVAL2 FSSB com error 2 (Group : i Axis : j)(Explanation) A communication error has occurred between the

robot controller PC board and servo amplifier.(Action 1) Check the communication cable (optical fiber)



(Action 3) Replace the servo amplifier module.Before continuing to the next step, perform acomplete controller back--up to save all yourprograms and settings. Failure to perform this couldresult in damage to equipment or lost data.



Axis control card

Fig.3.5 (36) SRVO--056 SVAL2 FSSB com error 2


62

(37)SRVO--057 SVAL2 FSSB disconnect (Group : i Axis : j)(Explanation) Communication was interrupted between the robot

controller PC board and servo amplifier.(Action 1) Check whether fuse FU1 in the power supply module

unit has blown.(Action 2) Check whether fuse FU1 in the servo amplifier

module has blown.(Action 3) Check the communication cable (optical fiber)



(Action 5) Replace the power supply module and the servoamplifier module.Before continuing to the next step, perform acomplete controller back--up to save all yourprograms and settings. Failure to perform this couldresult in damage to equipment or lost data.

(Action 6) Replace the robot controller PC board.(Action 7) Check the RMP cable of robot connection cable.

(+5V ground fault)



Fig.3.5 (37) SRVO--057 SVAL2 FSSB disconnect


63

(38)SRVO--058 SVAL2 FSSB init error (Group : i Axis : j)(Explanation) Communication was interrupted between the robot

controller PC board and servo amplifier module.(Action 1) Check whether fuse FU1 in the power supply module

have blown.If they have blown, see Section 3.6, “Troubleshootingfor Blown Fuse.”

(Action 2) Check whether seven segment LEDs on the servoamplifier module are on.If they are on, perform “Action 4” and all actions thatfollow it. If they are not on, perform “Action 3” andall actions that follow it.

(Action 3) Check whether connector CX1 on the power supplymodule is securely connected.

(Action 4) Check the communication cable (optical fiber)between the robot controller PC board and servoamplifier module. Replace it if it is faulty.


(Action 6) If the seven--segment LED on the servo amplifiermodule is glowing, replace the servo amplifiermodule. If the seven--segment LED on the servoamplifier module is not glowing, replace the powersupply module.Before continuing to the next step, perform acomplete controller back--up to save all yourprograms and settings. Failure to perform this couldresult in damage to equipment or lost data.




Fig.3.5 (38) SRVO--058 SVAL2 FSSB init error


64

(39)SRVO--059 SVAL2 Servo amp init error(Explanation) Servo amplifier initialization is failed.(Action 1) Check all connectors on the PSM and SVM. Make

sure they are installed correctly.(Action 2) Replace the power supply module and the servo

amplifier module.


Fig.3.5 (39) SRVO--059 SVAL2 Servo amp init error

(40)SRVO--061 SVAL2 CKAL alarm (Group : i Axis : j)(Explanation) This alarm occurs if the rotation speed count in the

pulse coder is abnormal (abnormal count clock).(Action) Replace the pulse coder.

NOTEIn this case, perform actions associated with DTERR,CRCERR, or STBERR first.

(41)SRVO--062 SVAL2 BZAL alarm (Group : i Axis : j)(Explanation) This alarm occurs if battery for pulse coder

absolute-position backup is empty.A probable cause is a broken battery cable or nobatteries in the robot.

(Action) Remove the cause of the alarm, set the systemvariable ($MCR.$SPC RESET) to TRUE, then turnthe power off and on again. Mastering is required.

(42)SRVO--063 SVAL2 RCAL alarm (Group : i Axis : j)(Explanation) This alarm occurs if the rotation speed count in the

pulse coder is abnormal (abnormal counter).(Action) Replace the pulse coder.

NOTEIn this case, perform actions associated with DTERR,CRCERR, or STBERR first.


65

(43)SRVO--064 SVAL2 PHAL alarm (Group : i Axis : j)(Explanation) This alarm occurs if the phase of the pulses generated

in the pulse coder is abnormal.(Action) Replace the pulse coder.

NOTEThis alarm might accompany the DTERR, CRCERR, orSTBERR alarm. In this case, however, there is no actualcondition for this alarm.

(44)SRVO--065 WARN BLAL alarm (Group : i Axis : j)(Explanation) The battery voltage for the pulse coder is lower than

the rating.(Action) Replace the battery.

(If this alarm occurs, turn on the AC power andreplace the battery as soon as possible. A delay inbattery replacement may result in the BZAL alarmbeing detected. In this case, the position data will belost. Once the position data is lost, mastering willbecome necessary.

(45)SRVO--066 SVAL2 CSAL alarm (Group : i Axis : j)(Explanation) The ROM in the pulse coder is abnormal.(Action) Replace the pulse coder.

NOTEThis alarm might accompany the DTERR, CRCERR, orSTBERR alarm. In this case, however, there is no actualcondition for this alarm.

(46)SRVO--067 SVAL2 OHAL2 alarm (Group : i Axis : j)(Explanation) The temperature inside the pulse coder or motor is

abnormally high, and the built--in thermostat hasoperated.

(Action 1) Check the operating conditions for the robot and relaxthe service conditions.

(Action 2) When power is supplied to the motor after it hasbecome sufficiently cool, if the alarm still occurs,replace the motor.

(47)SRVO--068 SVAL2 DTERR alarm (Group : i Axis : j)(Explanation) The serial pulse coder does not return serial data in

response to a request signal.--See actions on SRVO--070

(48)SRVO--069 SVAL2 CRCERR alarm (Group : i Axis : j)(Explanation) The serial data has disturbed during communication.

--See actions on SRVO--070


66

(49)SRVO--070 SVAL2 STBERR alarm (Group : i Axis : j)(Explanation) The start and stop bits of the serial data are abnormal.(Action 1) Make sure that the JF1 to JF3 connector of servo

amplifire module is connected tightly.(Action 2) Check that the shielding of the robot interconnection

cable (for the pulse coder) and the peripheral equipmentcable is connected securely to the grounding plate.

(Action 3) Check that each unit is grounded securely.(Action 4) Replace the servo amplifier module.(Action 5) Replace the pulse coder.(Action 6) Replace the robot interconnection cable (RMP).


Fig.3.5 (49) SRVO--070 SVAL2 STBERR alarm

(50)SRVO--071 SVAL2 SPHAL alarm (Group : i Axis : j)(Explanation) The feedback speed is abnormally high.(Action 1) If this alarm occurs together with the PHAL alarm

(No. 064), this alarm does not correspond to the majorcause of the failure.

(Action 2) Replace the pulse coder.

(51)SRVO--072 SVAL2 PMAL alarm (Group : i Axis : j)(Explanation) It is likely that the pulse coder is abnormal.(Action) Replace the pulse coder and remaster the robot.

(52)SRVO--073 SVAL2 CMAL alarm (Group : i Axis : j)(Explanation) It is likely that the pulse coder is abnormal or thepulse

coder has malfunctioned due to noise.(Action) Master the robot and enhance the shielding.

(53)SRVO--074 SVAL2 LDAL alarm (Group : i Axis : j)(Explanation) The LED in the pulse coder is broken.(Action) Replace the pulse coder, and remaster the robot.

(54)SRVO--075 WARN Pulse not established (Group : i Axis : j)(Explanation) The absolute position of the pulse coder cannot be

established.(Action) Reset the alarm, and jog the axis on which the alarm

has occurred until the same alarm will not occuragain. (Jog one motor revolution)


67

(55)SRVO--076 SVAL1 Tip Stick Detection (Group : i Axis : j)(Explanation) An excessive disturbance was assumed in servo

software at the start of operation. (An abnormal loadwas detected. The cause may be welding.)

(Action 1) Check whether the robot comes into collision withforeign matter. If a collision occurs, reset the system,then switch it to the jog feed mode to avoid thecollision.

(Action 2) Check whether the load settings are valid.(Action 3) Check whether the load weight is within the rated

range. If the weight exceeds the upper limit, decreaseit to the limit.(Use of the robot with a load exceeding the limitapplied may abnormally increase the assumeddisturbance, resulting in this alarm.)

(Action 4) Check each inter--phase voltage of the three--phaseinput (200 VAC) to the power supply module. If thevoltage is 170 VAC or lower, check the input powersupply voltage.



Fig.3.5 (60) SRVO--076 SVAL1 Tip Stick Detection

(56)SRVO--081 WARN EROFL alarm (Track enc : i)(Explanation) The pulse counter for line tracking has overflowed.

(57)SRVO--082 WARN DAL alarm (Track ebc : i)(Explanation) The line tracking pulse coder has not been connected.(Action 1) Check the pulse coder connection cable, and replace

it if necessary.(Action 2) Replace the pulse coder.

(58)SRVO--083 WARN CKAL alarm (Track ebc : i)(Explanation) This alarm occurs if the rotation speed count in the

pulse coder is abnormal (abnormal count clock).(Action) See the description about the SRVO--061 CKAL

alarm.


68

(59)SRVO--084 WARN BZAL alarm (Track enc : i)(Explanation) This alarm occurs if the backup battery for the absolute

position of the pulse coder has not been connected. Seethe description about the BZAL alarm (SRVO--062).

(60)SRVO--085 WARN RCAL alarm (Track ebc : i)(Explanation) This alarm occurs if the rotation speed count in the

pulse coder is abnormal (abnormal counter).(Action) See the description about the SRVO--063 RCAL

alarm.(61)SRVO--086 WARN PHAL alarm (Track enc : i)

(Explanation) This alarm occurs if the phase of pulses generated inthe pulse coder is abnormal. See the descriptionabout the PHAL alarm (SRVO--064).

(62)SRVO--087 WARN BLAL alarm (Track enc : i)(Explanation) This alarm occurs if the voltage of the backup battery

for the absolute position of the pulse coder is low. Seethe description about the BLAL alarm (SRVO--065).

(63)SRVO--088 WARN CSAL alarm (Track ebc : i)(Explanation) The ROM in the pulse coder is abnormal.(Action) See the description about the SRVO--066 CSAL

alarm.(64)SRVO--089 WARN OHAL2 alarm (Track enc : i)

(Explanation) The motor has overheated. See the description aboutthe OHAL2 alarm (SRVO--067).

(65)SRVO--090 WARN DTERR alarm (Track enc : i)(Explanation) Communication between the pulse coder and line

tracking interface board is abnormal. See thedescription about the DTERR alarm (SRVO--068).

(66)SRVO--091 WARN CRCERR alarm (Track enc : i)(Explanation) Communication between the pulse coder and line

tracking interface board is abnormal. See thedescription about the CRCERR alarm (SRVO--069).

(67)SRVO--092 WARN STBERR alarm (Track enc : i)(Explanation) Communication between the pulse coder and line

tracking interface board is abnormal. See thedescription about the STBERR alarm (SRVO--070).

(68)SRVO--093 WARN SPMAL alarm (Track enc : i)(Explanation) This alarm occurs if the current position data from the

pulse coder is higher than the previous position data.See the description about the SPHAL alarm(SRVO--071).

(69)SRVO--094 WARN PMAL alarm (Track enc : i)(Explanation) It is likely that the pulse coder is abnormal. See the

description about the PMAL alarm (SRVO--072).(70)SRVO--095 WARN CMAL alarm (Track enc : i)

(Explanation) It is likely that the pulse coder is abnormal or thepulsecoder has malfunctioned due to noise. See thedescription about the CMAL alarm (SRVO--073).

(71)SRVO--096 WARN LDAL alarm (Track enc : i)(Explanation) The LED in the pulse coder is broken. See the

description about the LDAL alarm (SRVO--074).


69

(72)SRVO--097 WARN Pulse not established (enc : i)(Explanation) The absolute position of the pulse coder cannot be

established. See the description about (SRVO--075).Pulse not established.

(73)SRVO--131 SVAL1 LVAL (PSM) alarm (Group : i Axis : j)(Explanation) The control power supply voltage (for example, +5

V) on the power supply module is abnormally low.The LED indication on the power supply module is“6” (LVAL).


Power supply module

Fig.3.5 (73) SRVO--131 SVAL1 LVAL(PSM) alarm


70

(74)SRVO--134 SVAL1 DCLVAL (PSM) alarm (Group : i Axis : j)(Explanation) The DC voltage (DC link voltage) of the main circuit

power supply on the power supply module isabnormally low. The LED indication on the powersupply module is “4.”

--If this alarm occurs during robot operation:(Action 1) Check the phase voltage of the three--phase input (200

VAC) to the power supply module. If it is 170 VACor lower, check the input power supply voltage.

(Action 2) Replace the power supply module.--If this alarm occurs before the magnetic contactor (MCC) is turnedon:(Action 1) Check the emergency stop PC board and the wiring

between the power supply module and magneticcontactor (MCC) for an abnormal condition.

(Action 2) Replace the magnetic contactor (MCC).(Action 3) Replace the emergency stop unit.(Action 4) Replace the power supply module.

Emergency stop unit


Magnetic contactor

Fig.3.5 (74) SRVO--134 SVAL1 DCLVAL (PSM) alarm


71

(75)SRVO--135 SVAL FSAL alarm (Group : i Axis : j)(Explanation) The internal cooling fan (s) of the servo amplifier

module (s) is abnormal. The LED indication on therelevant servo amplifier module is “1.”

(Action 1) Replace the fan motor of the servo amplifier module.(Action 2) Replace the servo amplifier module.

Servo amplifier module Servo amplifier module

Fan

Fig.3.5 (75) SRVO--135 SVAL FSAL alarm


72

(76)SRVO--136 SVAL1 DCLVAL alarm (Group : i Axis : j)(Explanation) The servo the DC current of amplifier (DC link

voltage) of the main power supply is abnormally low.The LED indication on the power supply modulebecomes “4”, and the LED indication on the servoamplifier module becomes “5”.

--This alarm occured in the robot operation.(Action 1) Check the phase voltage of the three--phase input

power (200 VAC) to the power supply module. If itis 170 VAC or lower, check the line voltage.


--If this alarm occurs before the magnetic contactor is turned on:(Action 1) Check the emergency stop PC board and the wiring

between the power supply module and electromagneticcontactor (MCC) for an abnormal condition.

(Action 2) Replace the magnetic contactor.(Action 3) Replace the E--stop unit.(Action 4) Replace the power supply module.


Power supply moduleMagnetic contactor

Fig.3.5 (76) SRVO--136 SVAL1 DCLVAL alarm


73

(77)SRVO--156 SVAL1 IPMAL alarm (Group : i Axis : j)(Explanation) Abnormally high current flowed through the main

circuit of the servo amplifier.The LED indications on the servo amplifier modulesare “8.”, “9.”, and “A.”.

(Action 1) Detach the motor power lines from the connectorsCZ2 of the servo amplifier modules, then turn on thepower. If this operation causes the error to recur,replace the servo amplifier module.

(Action 2) Detach the motor power lines from the connectorsCZ2 of the servo amplifier modules, then check theinsulation between GND and each of the motor powerlines U, V, and W individually. If a short--circuit isfound, the motor, robot interconnection cable, orintra--robot cable may be faulty. Examine each ofthem for any problem.

(Action 3) Detach the motor power lines from the connectorsCZ2 of the servo amplifier modules, then measure theresistance between the motor power lines U and V, Vand W, and W and U, using an ohmmeter with a verylow resistance range. If the three resistances aredifferent, the motor, robot connection cable, orintra--robot cable may be faulty. Examine each ofthem for any problem.Before taking (Action 4), make a backup copy of allthe programs and settings of the control unit.



Fig.3.5 (77) SRVO--156 SVAL1 IPMAL alarm


74

(78)SRVO--157 SVAL1 CHGAL alarm (Group : i Axis : j)(Explanation) The capacitor for the DC link voltage of the servo

amplifier module was not charged within thespecified time.

(Action 1) A short circuit may occur in the DC link voltage.Check the connection.

(Action 2) Replace the servo amplifier module.(Action 3) Replace the power supply module.


Fig.3.5 (78) SRVO--157 SVAL1 CHGAL alarm


75

(79)SRVO--201 SVAL1 Panel E--stop or SVEMG abnormal(Explanation) The EMERGENCY STOP button on the operator

panel was pressed, but the EMERGENCY STOP linewas not disconnected.

(Action 1) Check the EMERGENCY STOP button on theoperator panel, and replace it if necessary.

(Action 2) Check whether fuse FUS3 on the emergency stop PCboard is blown. Replace if it is blown.

(Action 3) Check whether +24 V is connected to EMGIN2 on theterminal block TBEB5 of the emergency stop PCboard by mistake. Correct any wrong wiring.

(Action 4) Replace the emergency stop unit.(Action 5) Replace the power supply module.

NOTEThis alarm might occur if the EMERGENCY STOP buttonis pressed slowly.

Power supply module

emergency stop button

Emergency stop unit

Fig.3.5 (79) SRVO--201 SVAL1 Panel E--stop or SVEMG abnormal


76

(80)SRVO--202 SVAL1 TP E--stop or SVEMG abnormal(Explanation) The EMERGENCY STOP button on the operator

panel was pressed, but the EMERGENCY STOP linewas not disconnected.

(Action 1) Check the teach pendant connection cable.(Action 2) Replace the teach pendant.(Action 3) Check whether +24 V is incorrectly connected to

FENCE2 on the terminal block TBEB5 of theemergency stop PC board. If it is incorrectlyconnected, connect it again.


NOTEThis alarm might occur if the EMERGENCY STOP buttonis pressed slowly.

Power supply moduleEmergency stop unit

Teach pendant

Teach pendant cable

Emergencystop button


FENCE2 terminal

Fig.3.5 (80) SRVO--202 SVAL1 TP E--stop or SVEMG abnormal


77

(81)SRVO--204 SVAL1 External (SVEMG abnormal) E--stop(Explanation) Although the switch connected across EMGIN1 and

EMGIN2 on the terminal block TBEB5 of theemergency stop PC board was pressed, theEMERGENCY STOP line was not disconnected.

(Action 1) Check whether +24 V is connected to SVOFF2 on theterminal block TBEB5 of the emergency stop PCboard by mistake. Correct any wrong wiring.


Power supply module

Emergency stop unit

Fig.3.5 (81) SRVO--204 SVAL1 External (SVEMG abnormal) E--stop


78

(82)SRVO--205 SVAL1 Fence open (SVEMG abnormal)(Explanation) The EMERGENCY STOP line was not disconnected

even though the switch connected between FENCE1and FENCE2 on the terminal block TBEB5 of theemergency stop PC board was open.

(Action 1) Check whether +24 V is connected to EMGIN2 on theterminal block TBEB5 of the emergency stop PCboard by mistake. Correct any incorrect wiring.


Power supply module

Emergency stop unit

Fig.3.5 (82) SRVO--205 SVAL1 Fence open (SVEMG abnormal)


79

(83)SRVO--206 SVAL1 Deadman switch (SVEMG abnormal)(Explanation) The DEADMAN switch was released when the teach

pendant was operable, but the EMERGENCY STOPline was not disconnected.

(Action 1) Check whether +24 V is incorrectly connected toFENCE1 or FENCE2 on the terminal block TBEB5of the emergency stop PC board. If it is incorrectlyconnected, connect it again.

(Action 2) Replace the teach pendant.(Action 3) Replace the emergency stop unit.(Action 4) Replace the power supply module.

Power supply module

Emergency stop unit

Fig.3.5 (83) SRVO--206 SVAL1 Deadman switch (SVEMG abnormal)


80

(84)SRVO--207 SVAL1 TP switch abnormal or door open(Explanation) The teach pendant is operable, and the deadman

switch has been grasped, but the EMERGENCYSTOP line is kept disconnected.

(Action 1) Check the teach pendant connection cable.(Action 2) Replace the teach pendant.(Action 3) Replace the emergency stop unit.

Emergency stop unit

Teach pendant

teach pendant cable

Fig.3.5 (84) SRVO--207 SVAL1 TP switch abnormal or door open


81

(85)SRVO--215 WARN Fuse blown (Aux axis)(Explanation) The fuse in the additional axis amplifier has blown.(Action 1) Check the cause and solve the problem, then replace

the fuse.

(86)SRVO--216 SVAL1 OVC (total) (Robot : i)(Explanation) The current (total current for five axes or six axes)

flowing through the motor is too large.(Action 1) Slow the motion of the robot where possible. Check

the robot operation conditions. If the robot is usedwith a condition exceeding the duty or load weightrobot rating, reduce the load condition value to thespecification range.

(Action 2) Check each inter--phase voltage of the three--phaseinput (200 VAC) to the power supply module. If thevoltage is 170 VAC or lower, check the input powersupply voltage.

Power supply module

Fig.3.5 (86) SRVO--215 WARN Fuse blown (Aux axis)


82

(87)SRVO--221 SVAL1 Lack of DSP (Group : i Axis : j)(Explanation) A controlled axis card corresponding to the set

number of axes is not mounted.(Action 1) Check whether the set number of axes is valid. If the

number is invalid, set the correct number.(Action 2) Replace the controlled axis card with a card

corresponding to the set number of axes.(Example)When six axes are set, a controlled axis card for sixor eight axes is available. For how to replace thecontrolled axis card, see II MAINTENANCE,Section 7.2 in this manual.



Fig.3.5 (87) SRVO--221 SVAL1 Lack of DSP (Group : i Axis : j)


83

(88)SRVO--222 SVAL1 Lack of Amp (Amp : i)(Explanation) The FSSB has no SVM.(Action 1) Check that the optical cable is securely connected to

the servo amplifier module.(Action 2) Replace the optical cable.(Action 3) Check whether power is properly supplied to the

servo amplifier module.


Fig.3.5 (88) SRVO--222 SVAL1 Lack of Amp (Amp : i)


84

(89)SRVO--233 SVAL1 TP disabled in T1, T2/Door open(Explanation) The teach pendant is disabled when the mode switch

is in the T1 mode or T2 mode position.(Action 1) During teaching operation, set the enable switch of

the teach pendant to Enable. Otherwise, set the modeswitch to AUTO mode.

(Action 2) Replace the emergency stop unit.(Action 3) Replace the teach pendant.(Action 4) The mode switch may be faulty. Replace the operator

panel.

Emergency stop unit

Teach pendant


FUS3

Mode switch

Fig.3.5 (89) SRVO--233 SVAL1 TP disabled in T1, T2/Door open


85

(90)SRVO--264 SVAL1 “E.STOP circuit abnormal 1”(Explanation) An error occurred in the emergency stop circuit.(Action 1) Check whether the CRR78 connectors on the

E--STOP unit and the CX3 connector of the powersupply module are connected securely.


Power supply module

Emergency stop unit

Fig.3.5 (90) SRVO--264 SVAL1 “E.STOP circuit abnormal 1”


86

(91)SRVO--265 SVAL1 E.STOP circuit abnormal 2(Explanation) When the servo amplifier is excited, the monitor

contact of the magnetic contactor (MCC) becomesfaulty.

(Action 1) Replace the magnetic contactor (MCC).(Action 2) Replace the emergency stop unit.(Action 3) Replace the power supply module.

Power supply module

Emergency stop unit

Magnetic contactor

Fig.3.5 (91) SRVO--265 SVAL1 E.STOP circuit abnormal 2


87

(92)SRVO--290 SVAL1 DClink HC alarm (Group : i Axis : j)(Explanation) The DC link current in the servo amplifier module(s)

is abnormal. The LED indication on the relevantservo amplifier module is “8.”

(Action 1) Detach the motor power lines from connector CZ2 ofthe servo amplifier module, then turn the power on.If this alarm persists, replace the servo amplifiermodule.

(Action 2) Detach the motor power lines from connector CZ2 ofthe servo amplifier module, then check the insulationbetween GND and each of U, V, and W of the motorpower lines. If a short circuit is detected, the motor,robot connection cable, or internal robot cable may bedefective. Check them for an abnormal condition.

(Action 3) Detach the motor power lines from connector CZ2 ofthe servo amplifier module, then use a high--precisionohmmeter to measure U--V, V--W, and W--Uresistances of the motor power lines. If the threeresistances differ, the motor, robot connection cable,or internal robot cable may be defective. Check themfor an abnormal condition.Before proceeding with (Action 4), back up allprograms and settings for the control unit.

(Action 4) Replace the robot control PC board.


Fig.3.5 (92) SRVO--290 SVAL1 DClink HC alarm


88

(93)SRVO--291 SVAL1 “IPM over heat (Group : i Axis : j)”(Explanation) The IPM in the servo amplifier overheats.

The LED indications on the servo amplifier modulesare “8.”, “9.”, and “A.”.

(Action 1) Check whether the servo amplifier module fan stops.(Action 2) Reduce the override because the use condition is too

hard.(Action 3) If this alarm is frequently issued, replace the amplifier

module.

(94)SRVO--295 SVAL1 SVM COM alarm (Group : i Axis : j)(Explanation) Communication between the servo amplifier

modules is abnormal. The LED indications on theservo amplifier modules are “P.”

(Action 1) If “SRVO -- 047 LVAL alarm” and “SRVO -- 131LVAL (PSM) alarm” also occur, the control powersupply voltage is low. Take measures against thesealarms.

(Action 2) Check the servo amplifier modules and cables forconnectors CX2A and CX2B of the power supplymodule, as well as their connection.

(Action 3) Replace the axis control card on the robot control PCboard.

(Action 4) Replace the servo amplifier modules.Before proceeding with (Action 5), back up allprograms and settings for the control unit.

(Action 5) Replace the robot control PC board.



Fig.3.5 (94) SRVO--295 SVAL1 SVM COM alarm


89

(95)SRVO--296 SVAL1 DCAL alarm (Group : i Axis : j)(Explanation) The regenerative discharge energy is too high to be

dissipated as heat. (To move the robot, the servoamplifier supplies energy to the robot. When goingdown, the robot moves along the vertical axis as thepotential energy reduces. If a reduction in thepotential energy is larger than the amount ofacceleration energy, the servo amplifier receivesenergy from the motor. This also occurs atdeceleration even when no gravity is applied. Theenergy that the servo amplifier receives from themotor is called regenerative energy. The servoamplifier dissipates this energy as heat. If the amountof the regenerative energy dissipated as heat issmaller than was received, the remainder is stored inthe servo amplifier, causing this alarm.) The LEDindication on the power supply module is “8”(DCAL: regenerative energy adder detection).

(Action 1) This alarm may occur if the robot is subjected tofrequent acceleration/deceleration or if the verticalaxis generates a large amount of regenerative energy.In this case, relax the service conditions.


Power supply module

Fig.3.5 (95) SRVO--296 SVAL1 DCAL alarm


90

(96)SRVO--297 SVAL1 DCLVAL alarm (Group : i Axis : j)(Explanation) An open--phase condition has occurred in the input

power supply to the main circuit on the power supplymodule. The LED indications on the power supplymodule is “E.”

(Action 1) Check the phase voltage of the three--phase input (200VAC) to the power supply module. If an open--phasecondition is detected, check the input power supply.


Power supply module

Fig.3.5 (96) SRVO--297 SVAL1 DCLVAL alarm

(97)SRVO--300 SVAL1 Hand broken/HBK disabledSRVO--302 SVAL1 Set Hand broken to ENABLE(Explanation) Although HBK was disabled, the HBK signal was

input.(Action 1) Press RESET on the teach pendant to release the

alarm.(Action 2) Check whether the hand broken signal is connected to

the robot. When the hand broken signal circuit isconnected, enable hand broken. (See IICONNECTION, Section 3.8 in this manual.)


Fig.3.5 (97) SRVO--300 SVAL1 Hand broken/HBK disabledSRVO--302 SVAL1 Set Hand broken to ENABLE


91

(98)SRVO--322 SVOFF input/E.STOP(Explanation) SVOFF1 and SVOFF2 on the terminal block TBEB5

of the emergency stop PC board are notshort--circuited. If a servo off input signal line isconnected across SVOFF1 and SVOFF2, the servooff input signal contact is open.

(Action 1) If the servo off input signal line is connected, close theservo off input signal contact.

(Action 2) Examine the cables and switches connected toSVOFF1 and SVOFF2.

(Action 3) If this signal is not used, short--circuit SVOFF1 andSVOFF2.

NOTEIf the system uses the servo off input signal, avoidshort--circuiting and disabling this signal. It is verydangerous. If the system has to be operated with the signalshort--circuited temporarily, a corresponding safetyprovision must be taken.

(Action 4) Replace the emergency stop unit.Before taking (Action 5), make a backup copy of allthe programs and settings of the control unit.


Emergency stop unitRobot controller P.C. board


Fig.3.5 (98) SRVO--322 SVOFF input/E.STOP


92

This section describes alarms that can occur when a fuse mounted on a PCboard or unit is blown and corresponding corrective actions.

(1) Fuses on the robot controller PC boardFUS1 : For generating power to the control circuitFUS2 : For protecting +24E output to peripheral device digital

input/output, end effector, ROT, and HBK

Name Problem caused by blown fuse Action

FUS1 The control power of the robot controller PC board is shut off.The teach pendant displays the initial screen.

1 Check the units (fans) and cables connected to the CP2 andCP3 connectors of the power supply unit to see if there is anyshort circuit.

2 Replace the DC/DC converter module.3 Replace the robot controller PC board.

FUS2 The teach pendant screen displays alarm information such asHand broken (SERVO -- 006) or Robot overtravel (SERVO --005).

1 Check that +24E used by the peripheral device is free from aground fault.

2 Examine the peripheral device connection cable.3 Check that +24E used by the end effector is free from a ground

fault.4 Examine the robot interconnection cable and intra--robot

cable.

FUS1 FUS2

3.6TROUBLESHOOTINGUSING FUSES


93

(2) Fuses on the emergency stop PC boardFUS3 : For monitoring the emergency stop circuitFUS4 : For controlling the emergency stop circuit and teach pendantFUS5 : For the brake circuit


FUS3 The teach pendant screen displays SVAL1 TP dis-abled in T1, T2/Door open (SERVO -- 233) and so forth.

Replace the emergency stop unit.

FUS4 The power supply to the teach pendant stops, thescreen display of the teach pendant disappears, andthe system enters the emergency stop state.

1 Examine the teach pendant cable for any problem.2 Examine the teach pendant for any problem.3 Check that the external emergency stop input and servo off input are

free from a ground fault and any other fault.

FUS5 Replace the emergency stop unit.The robot motor brake cannot be released, and alarminformation such as Large error in travel (SERVO --024), Large error at rest (SERVO -- 023), Positioningtime over (SERVO -- 036), or CLALM alarm (SERVO-- 050) is displayed.

1 Check that the robot interconnection cable (RMP) and intra--mechani-cal--unit cable are free from faults such as a ground fault and short--cir-cuit.

2 If an additional axis is used, check that the brake connection cable isfree from a ground fault, short--circuit, and any other fault.

3 If a brake power transformer is used, note that a faulty brake powertransformer can cause a too large current to flow. Replace the brakepower transformer.

4 Replace the emergency stop unit.

FUS3

FUS4

FUS5



94

(3) Fuse on the power supply module

FU1 : For protecting 200 VAC input to generate power to thecontrol circuit


FU1 ALL LEDs of the servo amplifiers go out.The teach pendant screen displays the FSSB disconnectionalarm or FSSB initialization alarm.

1 Replace the fuse (5 A) on the control PC board of the powersupply module.

2 Replace the power supply module.

FU1

Remove the face plate


95

(4) Fuse on the servo amplifier module

FU1 : For protecting +24 V input to generate power to the controlcircuit


FU1 ALL LEDs of the servo amplifier modules go out.The teach pendant screen displays the FSSB disconnectionalarm or FSSB initialization alarm.

1 Replace the fuse (3.2 A) on the control PC board of the servoamplifier module.

2 Replace the servo amplifier module.

FU1

Remove the control P.C. board


96

The printed circuit boards and servo amplifier are provided with alarmLEDs and status LEDs. The LED status and correspondingtroubleshooting procedures are described below.

Servo amplifier module1 (AMP1)Power supply module (PSM)

Servo amplifier module2 (AMP2)



3.7TROUBLESHOOTINGBASED ON LEDINDICATIONS


97

(1) TROUBLESHOOTING USING THE LEDS ON THE robotcontroller PC boardTo troubleshoot an alarm that arises before the teach pendant is readyto display, check the status LEDs (green) on the robot controller PCboard at power--on.After power--on, the LEDs light as described in steps 1 to 18, in theorder described. If an alarm is detected, the step in which the alarmoccurred can be determined from which LEDs are lit.

Step LED Action to be taken

1: After power--on, all LEDs arelit.

[Action1] Replace the CPU card* [Action2] Replace the robot controller PC board.

2: Software operation start--up. [Action1] Replace the CPU card* [Action2] Replace the robot controller PC board.

3: The initialization of dram onthe CPU card is completed.

[Action1] Replace the CPU card* [Action2] Replace the robot controller PC board.

4: The initialization of SRAMand DPRAM is completed.

[Action1] Replace the CPU card* [Action2] Replace the robot controller PC board.* [Action3] Replace the FROM/SRAM module.

5: The initialization of the com-munication IC is completed.

[Action1] Replace the CPU card* [Action2] Replace the robot controller PC board.* [Action3] Replace the FROM/SRAM module.

6: The loading of the basic soft-ware is completed.

* [Action1] Replace the robot controller PC board.* [Action2] Replace the FROM/SRAM module.

7: Basic software start--up. * [Action1] Replace the robot controller PC board.* [Action2] Replace the FROM/SRAM module.

8: Start--up of communicationwith the teach pendant.

* [Action1] Replace the robot controller PC board.* [Action2] Replace the FROM/SRAM module.

9: The loading of optional soft-ware is completed.

* [Action1] Replace the robot controller PC board.

10:DI/DO initialization * [Action1] Replace the FROM/SRAM module.* [Action2] Replace the robot controller PC board.

11:The preparation of the SRAMmodule is completed.

[Action1] Replace the axis control card.* [Action2] Replace the robot controller PC board.

[Action3] Replace the servo amplifier.

* If the robot controller PC board or FROM/SRAM module is replaced, the contents of memory (parameters,specified data, etc.) will be lost. Before you replace the unit, therefore, make a backup copy of the data.


98

Step Action to be takenLED

12:Axis control card initialization [Action1] Replace the axis control card.* [Action2] Replace the robot controller PC board.


13:Calibration is completed. [Action1] Replace the axis control card.* [Action2] Replace the robot controller PC board.


14:Start--up of power applicationfor the servo system

* [Action1] Replace the robot controller PC board.

15:Program execution * [Action1] Replace the robot controller PC board.

16:DI/DO output start--up. * [Action1] Replace the robot controller PC board.

17: Initialization is terminated. Initialization has ended normally.

18:Normal status Status LEDs 1 and 2 blink when the system is operating normally.


Axis control card FROM/SRAM module(under the CPU card)

CPU card


99

(2) TROUBLESHOOTING BY 7--SEGMENT LED INDICATOR

7--segment LEDindicator Description

[Description] A parity alarm condition has occurred in RAM on the CPU card installed on the robotcontroller PC board.

[Action1] Replace the CPU card.[Action2] Replace the robot controller PC board.

[Description] A parity alarm condition has occurred in RAM on the FROM/SRAM module installedon the robot controller PC board.

[Action1] Replace the FROM/SRAM module.[Action2] Replace the robot controller PC board.

“2”, “3”, and “4” are not displayed.

[Description] A servo alarm condition has occurred on the robot controller PC board.[Action1] Replace the axis control card.[Action2] Replace the robot controller PC board.

[Description] The SYSEMG alarm has occurred.[Action1] Replace the axis control card.[Action2] Replace the CPU card.[Action3] Replace the robot controller PC board.

[Description] The SYSFAIL alarm has occurred.[Action1] Replace the axis control card.[Action2] Replace the CPU card.[Action3] Replace the robot controller PC board.



100

(3) Troubleshooting using a fuse alarm LED

LED indication Failure description and required measure

[Description] A fuse (FUS1 or FUS2) is blown.Cause of the blowing of FUS1 and corrective actions

[Action1] Check whether the device which is connected to the RS--232--C/RS--422 portand requires the power supply of +24 V is sound.

[Action2] Faulty DC/DC converter moduleReplace the DC/DC converter module.

[Action3] Short--circuited surge absorber PVS1The system can be operated temporarily without PVS1. However, obtain andmount a new one at the earliest possible time.

[Action4] Faulty robot controller PC boardReplace the robot controller PC board.

Cause of the blowing of FUS2 and corrective actions[Action1] Check that +24E used by the peripheral device is free from a ground fault.[Action2] Examine the peripheral device connection cable.[Action3] Check that +24E used by the end effector is free from a ground fault.[Action4] Examine the robot interconnection cable and intra--robot cable.


101

Troubleshooting using an LED on the emergency stop PC board

LED indication Problem and corrective action

[Description] The fuse (FUS3, FUS4, or FUS5) is blown.Cause of the blowing of FUS3 and corrective action

[Action] The emergency stop PC board is faulty. Replace the emergency stop unit.Cause of the blowing of FUS4 and corrective actions

[Action1] Check that the teach pendant cable is sound.[Action2] Check that the teach pendant is sound.[Action3] Check that the external emergency stop input and servo off input are free from

a ground fault and any other fault.[Action4] The emergency stop PC board is faulty. Replace the emergency stop unit.

Cause of the blowing of FUS5 and corrective actions[Action1] Check that the robot interconnection cable (RMP) and intra--mechanical--unit

cable are free from a ground fault, short--circuit, and any other fault.[Action2] If an additional axis is used, check that the brake connection cable is free from

a ground fault, short--circuit, and any other fault.[Action3] If a brake power transformer is used, note that a faulty brake power transformer

can cause a too large current to flow. Replace the brake power transformer.[Action4] The emergency stop PC board is faulty. Replace the emergency stop unit.

Fuse FUS4

Fuse FUS3

Fuse FUS5


Emergency stop unit

FALM LED


102

Troubleshooting using the LED of the power supply moduleThe power supply module has a seven--segment LED. When takinga corrective action corresponding to the LED indication, see the alarmdisplayed on the teach pendant screen.


[Description] The voltage of the DC link of the main circuit is low.[Action1] The input power was instantaneously interrupted.

Check the power supply.[Action2] The input supply voltage is low. Check the power re-

quirements.[Action3] The power to the main circuit was shut off in the emer-

gency stop release state. Check the emergency stop cir-cuit (emergency stop PC board, magnetic contactor, ex-ternal emergency stop input, etc.).

[Description] The main circuit could not be charged within a predeter-mined period.

[Action1] The DC link is short--circuited. Check the connection.[Action2] The charge current controlling resistor is faulty. Replace

the power supply module.

[Description] The control power voltage is low.[Action] The input power is low. Check the power supply.

[Description] The voltage of the DC link of the main circuit is too high.[Action1] The regenerative power is too large. Change the operat-

ing conditions.[Action2] The regenerative resistor is faulty. Replace the power

supply module.

[Description] The regeneration amount is too large.[Action] Change the operating conditions. For instance, lower

the frequency of acceleration/deceleration.

[Description] The regenerative resistor was heated.[Action] Change the operating conditions. For instance, lower

the frequency of acceleration/deceleration.

[Description] The input power is in the open--phase state.[Action] Check the power supply.

dot part ofseven segment LED


103

Troubleshooting using the LED of the servo amplifier moduleThe servo amplifier module has a seven--segment LED. When takinga corrective action corresponding to the LED indication, see the alarmdisplayed on the teach pendant screen.


[Description] The internal cooling fan stopped.[Action1] Check that the fan is not blocked with a foreign sub-

stance.[Action2] Check that the fan connector is correctly connected.[Action3] The fan is faulty. Replace the fan.[Action4] Replace the servo amplifier module.

[Description] The control supply voltage is low.[Action1] Check the three--phase input voltage. (The voltage must

be the rated input voltage multiplied by 0.85 at least.)[Action2] Measure the voltage of 24--V power supplied from the

power supply module. (Normal: 22.8 V or higher)[Action3] Check the CXA2A/B connector and the cable.[Action4] Replace the servo amplifier module.

[Description] The voltage of the DC link of the main circuit is low.[Action1] Check that the DC link connection cable (bar) is securely

screwed.[Action2] If this alarm occurs in multiple servo amplifier modules,

take the action for alarm code 4 of the power supply mod-ule.

[Action3] Replace the servo amplifier module.

[Description] The communication among servo amplifiers cannot benormally performed.

[Action1] Check the CXA2A/B connector and the cable.[Action2] Replace the control PC board of the servo amplifier mod-

ule.[Action3] Replace the servo amplifier module.



104


[Description1] The IPM alarm was detected in the servo amplifiermod-ule.

[Action1] Detach the motor power lines from the connectors CZ2of the servo amplifier modules, and turn the power on.a) If this alarm does not occur, go to Action 2.

b) If this alarm occurs, replace the servo amplifiermodule.

[Action2] Detach the motor power lines from the connectors CZ2of the servo amplifier modules, and check the insulationbetween PE and each of the motor power lines U, V, andW.a) If the insulation is deteriorated, go to Action 3.

b) If the insulation is normal, replace the servo amplifi-er module.

[Action3] Separate the motor and power line, then check whetherthe motor or power line has deteriorated insulation.a) If the motor insulation is deteriorated, replace the

motor.

b) If the power line insulation is deteriorated, examinethe robot interconnection cable or intra--robot cable.

“8.”, “9.”, and “A.” represent that an alarm occurs on the L--axis, M--axis, and N--axis respectively.

[Description2] The IPM alarm (overheat) was detected in the servoamplifier module.

[Action1] Check that the internal cooling fan does not stop.[Action2] Check that the motor is operated at its continuous rating

or lower.[Action3] Check that the cooling capability of the cabinet is not low-

ered. (Check the fan unit and heat exchanger.)[Action4] Check that the ambient temperature is not high.[Action5] Replace the servo amplifier module.



105


[Description] An abnormal current is flowing to the servo motor.[Action1] Check that the servo parameters are set to default val-

ues. If this alarm occurs only at a sudden accelerationor deceleration, the motor operating conditions may betoo harsh. Increase the acceleration/deceleration timeconstant and observe the operation.

[Action2] Detach the motor power lines from the connectors CZ2of the servo amplifier modules, then turn on the power.a) If this alarm does not occur, go to Action 2.

b) If this alarm occurs, replace the servo amplifiermodule.

[Action3] Detach the motor power lines from the connectors CZ2of the servo amplifier modules, then check the insulationbetween PE and each of the power lines U, V, and W.a) If the insulation is deteriorated, go to Action 3.

b) If the insulation is normal, replace the servo amplifi-er.

[Action4] Separate the motor and power line, then check whetherthe motor or power line has deteriorated insulation.a) If the motor insulation is deteriorated, replace the

motor.

b) If the power line insulation is deteriorated, examinethe robot interconnection cable and intra--robotcable.

“b”, “C”, and “d” represent that an alarm occurs on the L--axis, M--axis,and N--axis respectively.


106

(Check 1) On the status screen, check the position deviation in thestopped state. To display the position deviation, press thescreen selection key, and select STATUS from the menu.Press F1, [TYPE], select AXIS from the menu, then pressthe F4, PULSE.(Corrective action)Correct the parameters related to return to the referenceposition (positioning).

(Check 2) Check whether the motor axis can be positioned normally.(Corrective action)If the motor axis can be positioned normally, check themechanical unit.

(Check 3) Check the mechanical unit for backlash.(Corrective action)Replace a faulty key of motor shaft or other faulty parts.

(Check 4) If checks 1 to 3 show normal results(Corrective action)Replace the pulse coder and robot controller PC board.

3.8POSITION DEVIATIONFOUND IN RETURNTO THE REFERENCEPOSITION(POSITIONING)


107

(Check 1) Check the settings of parameters such as the position loopgain parameter.(Corrective action)Correct parameters.

(Check 2) Check the mechanical unit for backlash.(Corrective action)Replace a faulty key of motor shaft or other faulty parts.

3.9VIBRATIONOBSERVED DURINGMOVEMENT


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The following explains checking and corrective action required if therobot cannot be operated manually after the controller is turned on:

(1) Check and corrective action to be made if manual operation isimpossible

(Check 1) Check whether the teach pendant is enabled.(Corrective action)Turn on the teach pendant “enable”.

(Check 2) Check whether the teach pendant is handled correctly.(Corrective action)To move an axis by manual operation, press the axisselection key and case shift key at the same time.Set the override for manual feed to a position other than theFINE and VFINE positions.

(Check 3) Check whether the ENBL signal of the peripheral devicecontrol interface is set to 1.(Corrective action)Place the peripheral device control interface in the ENBLstatus.

(Check 4) Check whether the HOLD signal of the peripheral devicecontrol interface is on (hold status). (Check whether thehold lamp on the teach pendant is on.)(Corrective action)Turn off the HOLD signal of the peripheral device controlinterface.

(Check 5) Check whether the previous manual operation has beencompleted.(Corrective action)If the robot cannot be placed in the effective area because ofthe offset of the speed command voltage preventing theprevious operation from being completed, check the positiondeviation on the status screen, and change the setting.

(Check 6) Check whether the controller is in the alarm status.(Corrective action)Release the alarm.

(2) Check and corrective action to be taken if the program cannot beexecuted

(Check 1) Check whether the ENBL signal for the peripheral-devicecontrol interface is on.(Corrective action)Put the peripheral-device control interface in the ENBL state.

(Check 2) Check whether the HOLD signal for the peripheral-devicecontrol interface is on. (Check whether the HOLD lamp onthe teach pendant is on.)(Corrective action)If the HOLD signal is on, turn it off.

3.10MANUALOPERATIONIMPOSSIBLE


109

(Check 3) Check whether the previous manual operation has beencompleted.(Corrective action)If the robot cannot be placed in the effective area because ofthe offset of the speed command voltage, which prevents theprevious operation from being completed, check the positiondeviation on the status screen, then change the setting.

(Check 4) Check whether the controller is in the alarm status.(Corrective action)Release the alarm.

4. PRINTED CIRCUIT BOARDS B--81525EN--1/01MAINTENANCE

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4 PRINTED CIRCUIT BOARDS

The printed circuit boards are factory-set for operation. Usually, you donot need to set or adjust them. This chapter describes the standard settingsand adjustment required if a defective printed circuit board is replaced.It also describes the test pins and the LED indications.The standard printed circuit board includes the main unit printed circuitboard and one or more cards or modules installed horizontally to themain--unit printed--circuit board.These PC boards have interface connectors, LED indicators, and a plasticpanel at the front. At the rear, there is a backplane connector.

B--81525EN--1/01 4. PRINTED CIRCUIT BOARDSMAINTENANCE

111

CPU card

Total version

Axis control card

FROM/SRAM moduleunder the CPU card DC/DC converter module

Fig.4.1 Robot controller PC board

Name Board Specification Note

Robot controller PCboard A16B--3200--0450 I/O Link master/slave switche-

able, SDI/SDO = 28/24

DC/DC convert module A20B--8100--0721

CPU card A20B--3300--0106 SDRAM 8M (Standard)

A20B--3300--0107 SDRAM 16M

Axis control card A20B--3300--0241 6--axis

FROM/SRAM module A20B--3900--0181 FROM 16M, SRAM 0.5M :Standard

A20B--3900--0160 FROM 16M, SRAM 1MB

A20B--3900--0161 FROM 16M, SRAM 2MB

A20B--3900--0162 FROM 32M, SRAM 3MB

4.1ROBOT CONTROLLERPC BOARD(A16B--3200--0450)


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(1) LEDsSeven segment LED Description

A parity alarm occurred in a RAM of the main CPUcard on the Robot controller PC board.

A parity alarm occurred in a RAM of the FROM/SRAM module on the Robot controller PC board.

“2”, “3”, and “4” are not displayed.

A servo alarm occurred on the Robot controller PCboard.

SYSEMG occurred.

SYSFAIL occurred.This number appears temporarily after the power isswitched on, but it is not abnormal.


113

Status LED Description

STATUSLED

Indicates the system operating status.

Status LED Description

FUSEALARMLED

A fuse (FUS1 or FUS2) was blown.


114

(2) Correspondence between driver ICs and DODriver IC specification: A76L--0151--0062

Driver IC name DO signal name

H9 SDO101, SDO102, SDO103, SDO104

G9 SDO105, SDO106, SDO107, SDO108

K9 SDO109, SDO110, SDO111, SDO112

J9 SDO113, SDO114, SDO115, SDO116

J13 SDO119, SDO120, SDO81, Brake control (internal circuit)

H13 SDO82, SDO83, SDO84, Reserved

J6 RDO1, RDO2, RDO3, RDO4

J4 RDO5, RDO6, SDO117, SDO118

(3) Communication ICIf the teach pendant displays nothing because of a damaged teachpendant connection cable or another reason, the followingcommunication driver or receiver may be damaged.

IC name Name and usage Drawing number

G17 75172, driver A76L--0151--0098

G16 75173, receiver A76L--0151--0099


115

Total version

Fig.4.2 Emergency stop control PC board

4.2EMERGENCY STOPPC BOARD(A20B--1008--0022,--0023)


116

Total version

Fig.4.3 Backplane PC Board

4.3BACKPLANE PCBOARD(A20B--2003--0330)

B--81525EN--1/01 5. SERVO AMPLIFIERSMAINTENANCE

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5 SERVO AMPLIFIERS

The servo amplifiers are factory-set for operation. Usually, you do notneed to set or adjust them.This chapter describes the standard settings and adjustment required if adefective servo amplifier is replaced. It also describes the use of test pinsand meanings of the LED indications.

Table 5 Servo amplifier specifications

Robot Power supply module Servo amplifier module1 Servo amplifier module2

LR Mate 100iB

A06B--6115--H001(αPSMR--1i)

A06B--6114--H205(αSVM--20/20i)

A06B--6114--H302(αSVM--10/10/10i)

LR Mate 100iB L M L M NJ1 J2 J3 J4 J5

LR Mate 200iB

A06B--6115--H001(αPSMR--1i)

A06B--6114--H302(αSVM--10/10/10i)

A06B--6114--H302(αSVM--10/10/10i)

LR Mate 200iB L M N L M NJ1 J2 J3 J4 J5 J6

5. SERVO AMPLIFIERS B--81525EN--1/01MAINTENANCE

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380 360

60 172

Fig.5.1.1 Outline drawing of power supply module PSM (A06B--6115--H001)

5.1OUTLINE DRAWINGS

5.1.1Power Supply ModulePSM (A06B--6115--H001)


119

380 360

60 172

Fig.5.1.2 Outline drawing of servo amplifier modules (A06B--6114--H205, A06B--6114--H302)

5.1.2Servo Amplifier Module(A06B--6114--H205,A06B--6114--H302)

5. SERVO AMPLIFIERS B--81525EN--1/01MAINTENANCE

120

The power supply module has a seven--segment LED. When taking acorrective action corresponding to the LED indication, see the alarmdisplayed on the teach pendant screen.

LED indication Description

The magnetic contactor controlled by the power supply module is inthe off state and is not ready for driving the motor.

The magnetic contactor controlled by the power supply module is inthe on state and is ready for driving the motor.

The voltage of the DC link of the main circuit is low.

The main circuit cannot be charged within a predetermined period.

The control power voltage is low.

The voltage of the DC link of the main circuit is too high.

The regeneration amount is too large.

The regenerative resistor was heated.

The input power is in the open--phase state.

5.2LED OF SERVOAMPLIFIER

5.2.1LED of Power SupplyModule



121

The servo amplifier module has a seven--segment LED. When taking acorrective action corresponding to the LED indication, see the alarmdisplayed on the teach pendant screen.

LED indication Description

The main circuit in the servo amplifier module is in the off state and isnot ready for driving the motor.

The main circuit in the servo amplifier module is in the on state and isready for driving the motor.

The internal cooling fan stopped.

The control power voltage is low.

The voltage of the DC link of the main circuit is low.

The communication among servo amplifier modules cannot be normal-ly performed.

a) The IPM alarm was detected in the servo amplifier module.

b) The IPM alarm (overheat) was detected in the servo amplifier mod-ule.


An abnormal current is flowing to the servo motor.

“b”, “C”, and “d” represent that an alarm occurs on the L--axis, M--axis,and N--axis respectively.

5.2.2LED of Servo AmplifierModule


B--81525EN--1/01MAINTENANCE6. SETTING THE POWER SUPPLY

122

6 SETTING THE POWER SUPPLY

The power supply is factory-set for operation. Usually, you do not needto set or adjust it.

B--81525EN--1/01 MAINTENANCE 6. SETTING THE POWER SUPPLY

123

+24E

+24V--15V+15V+5V+3.3V

Backplane

AC input220, 380, 415,440, 500 VAC3φ

Process I/O

CRM2CRM4

+24F+24E FUSE1

board

+24V

JD17

+24E

+24E

+24E

CRM81

CRM79

CRM82

FUS2

FUS1 CP5

CP8B

BATTERYDC/DCconvertermodule+5V, +3.3V+15V, --15V

FAN

Powersupplyunit

AC/DC+24V

CN1

FUS3 FUS4 FUS5

FU1CX1

CZ1

Power supply module

Servo amplifier

Motor

End Effector

Motor powersupplyMotor brake

Pulsecoder

Robot

Peripheral device(option)

Handy file etc.

Peripheral device

Teach pendant

+24T

CP5B CRS1Monitor circuit

Brakecircuit

Emergency stopunit

Circuitprotector

200VAC

3φ

2φ 200VAC 2φ

200VAC

Magneticcontactor(MCC)

Main circuitDC link

AC/DC+24V

DC/DC+5V

Invertercircuit

CXA2A L+, L--

CXA2B

JF1--3

L+, L--

CZ2 L--N

Emergen-cy stopcircuit

Servoamplifiermodule

Emergency stopprint board

Robot controllerP.C. board

+24V

+24E

Peripheral device(option)

TBEB3

CP5A CRR77

regenerativeresistor

Circuitprotector

Trans-former

Fig. 6.1 Block diagram of the power supply

6.1BLOCK DIAGRAMSOF THE POWERSUPPLY

B--81525EN--1/01MAINTENANCE6. SETTING THE POWER SUPPLY

124

The power supply unit need not be set or adjusted.

Table 6.2 Rating of the Power supply unit

Output Rated voltage Tolerance

+24V +24V +23V to +25V

The power supply module need not be set or adjusted.

Table 6.3 Rating of the Power supply module

Output Rated voltage Tolerance

+5V +5.1V 3%

+3.3V +3.3V 3%

+15V +15V 10%

--15V --15V 10%

6.2CHECKING THEPOWER SUPPLYUNIT

6.3CHECKING THEPOWER SUPPLYMODULE

B--81525EN--1/01 MAINTENANCE 6. SETTING THE POWER SUPPLY

125

One of the transformer connections is selected according to the powervoltage.

Rated voltage Transformer specification

220, 380, 415,440, 500V A80L--0022--0009

Transformer

Teminal arrangement

Fig.6.4 Transformer Installation Position and Terminal Block

Table 6.4 Transformer Tap Selection

PowerPrimary side tap connection

Connec-Powervoltage

L1 L2 L3 Connection line

Connection type

220V 4 9 14 4-15 9-5 14-10 Delta n

380V 4 9 14

415V 3 8 135 10 15 Star Y

440V 2 7 125-10-15 Star Y

500V 1 6 11

6.4SELECTING THETRANSFORMERCONNECTION

7. REPLACING A UNIT B--81525EN--1/01MAINTENANCE

126

7 REPLACING A UNIT

This section explains how to replace each unit in the control section.

WARNINGBefore you start to replace a unit, turn off the control unitmain power. Also keep all machines in the area of the controlunit switched off. Otherwise, you could injure personnel ordamage equipment.

B--81525EN--1/01 7. REPLACING A UNITMAINTENANCE

127

CAUTIONSWhen you replace printed--circuit boards, observe thefollowing cautions:

1 Keep the control unit power switched off.2 When you remove a printed--circuit board, do not touch the

semiconductor devices on the board with your hand ormake them touch other components.

3 Make sure that the replacement printed--circuit board hasbeen set up appropriately. (Setting plug etc.)

4 If the backplane board, power supply unit, or Robotcontroller PC board (including cards and modules) isreplaced, it is likely that robot parameters and taught dataare lost. Before you start to replace these components, savea backup copy of the robot parameters and taught data toa memory card, floppy disk, or any other external memorydevice.

5 Before you disconnect a cable, note its location. If a cableis detached for replacement, reconnect it exactly as before.

7.1REPLACING THEPRINTED--CIRCUITBOARDS


128

When replacing the backplane board, do so together with the plastic rack.

(1) Detach the cables from the robot controller PC board and boards onthe backplane board.

CAUTIONWhen you remove the main robot controller PC Board, besure that the battery is good (3.1--3.3VDC) and it is installedcorrectly. USE STATIC PROTECTION.

(2) Remove the robot controller PC board and boards from the rack. (SeeSection 7.1.2.)

(3) Detach the grounding cable from the backplane unit.(4) Loosen the retaining screws in the upper section of the rack. Remove

the retaining screws from the lower section of the rack.(5) Side rack up and out.(6) To replace the backplane and rack, reverse steps (1) -- (6).

CAUTIONThere is a possibility of data loss when a backplane--mounted printed circuit board is replaced. Be sure to backup all program and setup data on a floppy disk beforeproceeding.

M5 nut (2 places)

Backplane board

Fig.7.1.1 Replacing the Backplane Board

7.1.1Replacing theBackplane Board (Unit)


129

The backplane unit incorporates the power unit, Robot controller PCboard, and option boards. There are two types of option boards: Full--sizeboard and mini--size board. A full--size board occupies one slot. Amini--size board uses part of a full--size board.

CAUTIONBefore starting replacement, turn off the control unit mainpower. The robot controller PC board is equipped withbattery--backed memory devices for holding robotparameters and taught data, for example. When the Robotcontroller PC board is replaced, the data in the memorydevices is lost.

(1) Detach the cable from the printed--circuit board, whichever is to bereplaced.

(2) Pinch the barbed handles on the upper and lower sections of the boardto unlatch it, then pull it toward you.

(3) Place the replacement board on the rail in the appropriate slot of therack, then push it in gently by the handles until it is latched.

(4) There are two rails in the robot controller PC board SLOT (slot 1).When inserting the robot controller PC board, align it to theright--side rail.

Slot 1

Slot 2

Slot 1

Slot 10

Slot 9Rail(Left)

Rail(Right)

Barbedhandles

Barbedhandles

Option slot

zoom

Fig.7.1.2 Replacing the Robot Controller PC Board and Printed--CircuitBoards on the Backplane Unit

7.1.2Replacing the RobotController PC Boardand Printed--CircuitBoards on theBackplane Unit


130

The board is at the emergency stop unit.

(1) Detach all cables from the emergency stop unit consists of theemergency stop PC board and the power supply unit. The terminalblocks (TBEB5) are of a connector type. Pull out the upper terminalblock sections.

(2) Remove four retaining nuts from the emergency stop unit (1, 2), andreplace the emergency stop unit.

(3) Remove six retaining screws from the emergency stop PC board (3),and replace the emergency stop PC board.

2 Remove the back nuts (2--M5)

1 Remove the front nuts(2--M5)

3 Remove thescrews (6--M3)

Fig.7.1.3 Emergency stop PC board replacement

7.1.3Replacing theEmergency Stop PCBoard


131

CAUTIONBefore you start to replace a card or module, make a backupcopy of robot parameters and taught data. If the FROM/SRAMmodule is replaced, memory contents are lost.

Demounting a Card(1) Pull outward the clip of each of the two spacers used to secure the card

PCB, then release each latch.(2) Extract the card upward.

Card Card

Card

Card

Spacer

Spacer

Connector

Connector

Card

Fig.7.2 (a) Demounting a card

7.2REPLACING CARDSAND MODULES ONTHE ROBOTCONTROLLER PCBOARD


132

Mounting a Card(1) Check that the clip of each of the two spacers is latched outward, then

insert the card into the connector.(2) Push the clip of each spacer downward to secure the card PCB.

Card

CardCard

Card

Spacer

Spacer

Connector

Connector

CardCard

Fig.7.2 (b) Mounting a card


133

Demounting a module

CAUTIONWhen replacing the module, be careful not to touch themodule contact. If you touch the contact inadvertently, wipeout dirt on the contact with a clean cloth.

(1) Move the clip of the socket outward. (a)(2) Extract the module by raising it at a 30 degree slant and pulling

outward.

Mounting a module(1) Insert the module at a 30 degree slant into the module socket, with

side B facing upward. (b)(2) Push the module inward and downward until it is locked. (c)

(a)

(b)

(c)

Fig.7.2 (c) Demounting/Mounting a module


134

Removing the DC/DC converter module(1) Unscrew the screws (3--M3).(2) Pull out the module.

Mounting the module(1) Insert the module to the connector.(2) Screw the screws (3--M3).

DC/DC converter module

screws(3--M3)

Fig.7.2 (d) Mounting and removing the DC/DC converter module

Figure 7.2 (e) shows the locations of the cards and modules.

CPU card

Total version

Axis control card

FROM/SRAM moduleunder the CPU card DC/DC converter module

Fig.7.2 (e) Locations of Cards and Modules


135

WARNINGBefore you start replacement procedure, turn off the mainpower to the control unit. Otherwise you could injurepersonnel or damage equipment.

(1) Detach the cable from the transformer.

(2) Remove the two nuts (M5) securing the transformer, then replace thetransformer.

(3) Re--connect the cable.

Remore the nuts (2--M5)

Fig.7.3.1 Replacing the brake power transformer

7.3REPLACING THETRANSFORMER

7.3.1Replacing the BrakePower Transformer


136

(1) Detach the cables from the transformer.

(2) Remove the two screws (M5) securing the transformer and thenreplace the transformer.

(3) Connect the detached cables to the transformer.

Remove two screws (M5)

Fig.7.3.2 Replacing the Power Transformer

7.3.2Replacing the PowerTransformer


137

WARNINGBefore you start replacement, turn off the control unit mainpower.

B--cabinet(1) Detach the cables from the emergency stop unit.

(2) Remove retaining screws (4--M4) from the emergency stop unit, andreplace the emergency stop unit.

(3) Reconnect the cables.

2 Remove the back nuts(2--M5) screws

1 Remove the front nuts(2--M5) screws

Nut (4--M5)

Fig.7.4 Replacing the Emergency Stop Unit

7.4REPLACING THEEMERGENCY STOPUNIT


138

WARNINGBefore starting the replacement, turn off the control unitmain power. Otherwise you could injure personnel ordamage equipment.

(1) Detach the cable from the magnetic contactor (MCC).

(2) Holding down the magnetic contactor (MCC) a little, remove theMCC from the DIN rail.

(3) Mount a new magnetic contactor (MCC) on the DIN rail.

(4) Re--connect the cable.

Magnetic contactor (MCC)

Fig.7.5 Replacing the magnetic contactor

7.5REPLACING THEMAGNETICCONTACTOR


139

WARNINGBefore you start replacement, turn off the control unit mainpower. Otherwise you could injure personnel or damageequipment.

The following is the procedure for replacing the power supply module andservo amplifier module.

(1) Detach the cable from the servo amplifier. Remove the jumperconnecting the DC link (L+ and L--).

(2) Remove the two nuts from the top of the servo amplifier.

(3) Mount a new servo amplifier, reversing the removal step of (2).

(4) Re--connect the cable and re--mount the jumper connecting the DClink (L+ and L--).

Nut(2--M5)

Power supplymodule

servo amplifiermodule

Fig.7.6 Replacing the servo Amplifier

7.6REPLACING SERVOAMPLIFIERS


140

The specifications of the teach pendant vary with its use. When youreplace the teach pendant, check its specifications carefully.

(1) Be sure that the power of a robot controller is off.

(2) Detach the cable from the teach pendant.

(3) Replace the teach pendant.

Detach or attach the cable by rotatingthe connector retaining ring.

Fig.7.7 Replacing the Teach Pendant

7.7REPLACING THETEACH PENDANT


141

The control section fan motor can be replaced without using a tool. Thefan motor is mounted on the fan unit rack.

(1) Be sure that the power of a robot controller is off.

(2) Put your finger in the dent in the upper section of the fan unit, and pullthe fan unit until it is unlatched.

(3) Lift the fan unit slightly, and dismount it from the rack.

(4) Place a replacement fan on the upper section of the rack, and slide itgently until it is latched.

Fan motor connector

Fan motor

Pull the fan motor unittoward you to unlatch it.

Fig.7.8 Replacing the Control Section Fan Motor

7.8REPLACING THECONTROL SECTIONFAN MOTOR


142

The fan motor of the servo amplifier control unit can be replaced withoutusing tools. The fan unit is mounted at the top of the servo amplifier.

(1) Check that the robot controller is turned off.

(2) Holding the two lugs, pull up the fan unit in the direction of the arrow.

(3) Place a new fan unit at the top of the servo amplifier, and slightly pressit in.

Holding the two lugs, pull up thefan unit in the direction of the arrow(rightward in the figure).

When mounting the fan motor, notethe orientation of the fan motor andconnector.

Lug

WhiteBlackRed

Note the orientationof the connector key.

Fan unit (for width of 60 mm)

Fig.7.9 Replacing the fan motor of the servo amplifier control unit

7.9REPLACING THEFAN MOTOR OF THESERVO AMPLIFIERCONTROL UNIT


143

WARNINGBefore starting the replacement, turn off the control unitmain power. Never touch the fan motor while it is rotating.

Door fan unit

(1) Unscrew the four fastening screws (M4).

(2) Detach the cable from the fan unit.

(3) Mount a spare fan unit, reversing the removal procedure.Heat exchanger

(1) Detach the cable from the heat exchanger.

(2) Remove the six fastening nuts (M4), and pull the heat exchangertoward you.

(3) Detach the wiring from the door fan unit.

(4) Mount a spare heat exchanger, reversing the removal procedure.

Screws (4--M4)Nut (4--M5)

Door fan unit

Heat exchange

Fig.7.10 Replacing the door fan unit and heat exchanger

7.10REPLACING THEDOOR FAN UNIT ANDHEAT EXCHANGER


144

(1) Detach the cable from the circuit protector on the operator panel andthe grounding line from the door.

(2) Detach the cable (JD17) from the robot controller PC board and thecable (CRT12) from the emergency stop PC board.

(3) Unscrew the four screws (M3) fastening the operator panel, andremove the operator panel.

(4) Mount a new operator panel, reversing the removal steps of (1) to (3).

Screw (4--M3)

Fig.7.11 Replacing the operator panel

NOTEThe operator panel comprises the panel itself and thecables connected to the robot controller PC board andemergency stop PC board.

7.11REPLACING THEOPERATOR PANEL


145

The power supply unit is mounted on the emergency stop unit.

(1) Detach all the cables from the emergency stop unit (emergency stopPC board and power supply unit).

(2) Pull out the connector--type terminal block (TBEB5) at the top.

(3) Remove the four nuts (1 and 2) fastening the emergency stop unit, andremove the emergency stop unit.

(4) Unscrew the four screws fastening the power supply unit, and replacethe power supply unit.

1 Remove the front nuts(2--M5)

3 Remove the screws (4--M3)

2 Remove the back nuts (2--M5)

Fig.7.12 Replacing the power supply unit

7.12REPLACING THEPOWER SUPPLYUNIT


146

If a fuse of the control unit is blown, find out the cause, take an appropriateaction, then replace the fuse.

The robot controller PC board has the following fuses.

FUS1: For detecting a problem in the circuit on the robot controller PCboard: A60L--0001--0046#7.5If this fuse is blown, the DC/DC converter module or a deviceconnected to the RS--232--C/RS--422 port may be faulty. If thedevice connected to the RS--232--C/RS--422 port is not faulty,replace the DC/DC converter module.

FUS2: For protecting the 24V output to the peripheral device:A60L--0001--0046#7.5If this fuse is blown, the wiring to the peripheral device and a cablemay be incorrect or damaged.

FUS1 FUS2

Fig.7.13.1 Replacing a fuse on the robot controller PC board

7.13REPLACING A FUSE

7.13.1Replacing a Fuse onthe Robot ControllerPC Board


147

The emergency stop PC board has the following fuses.

FUS3: For monitoring the emergency stop circuit: A60L--0001--0046#1.0If this fuse is blown, the emergency stop PC board may be faulty.Replace the emergency stop PC board.

FUS4: For protecting the 24V output to the emergency stop circuit andteach pendant: A60L--0001--0046#1.0If this fuse is blown, the emergency stop circuit may be incorrectlyrouted, or the teach pendant or teach pendant cable may be faulty.Check the routing of the emergency stop circuit, and replace theteach pendant and teach pendant cable.

FUS5: For monitoring the emergency stop circuit: A60L--0001--0245#GP20If the fuse is blown, the brake circuit may be faulty. Examine thebrake, robot, and robot interconnection cable. Alternatively,replace the emergency stop PC board.

FUS3

FUS4

FUS5


Fig.7.13.2 Replacing a fuse on the emergency stop PC board

7.13.2Replacing a Fuse onthe Emergency StopPC Board


148

The power supply module has the following fuse.

FU1: For protecting the 200VAC input for generating power to thecontrol circuit: A60L--0001--0359If the fuse is blown, the power supply module may be faulty.Replace the power supply module.

FU1

Remove the face plate

Fig.7.13.3 Replacing the fuse on the power supply module

7.13.3Replacing the Fuse onthe Power SupplyModule


149

The servo amplifier module has the following fuse.

FU1: For protecting the +24 V input for generating power to the controlunit: A60L--0001--0290#LM32CIf this fuse is blown, the servo amplifier module may be faulty.Replace the servo amplifier module.

FU1

Remove the control P.C. board

Fig.7.13.4 Replacing the fuse on the servo amplifier module

7.13.4Replacing the Fuse onthe Servo AmplifierModule


150

A relay may have a poor contact or deposition after long hours of use. Ifany of these problems occur, replace the relay.

The emergency stop PC board has the following relays.

KA6: For external emergency stop output: A58L--0001--0192#1509AKA7: For brake control: A58L--0001--0192#1997R

KA6

KA7


Fig.7.14.1 Replacing a relay on the emergency stop PC board

7.14REPLACING ARELAY

7.14.1Replacing a Relay onthe Emergency StopPC Board


151

The programs, and system variables are stored in the SRAM in the Robotcontroller PC board. The power to the SRAM memory is backed up bya lithium battery mounted on the front panel of the Robot controller PCboard. The above data is not lost even when the main battery goes dead.A new battery can maintain the contents of memory for about 4 years(Note).When the voltage of the battery becomes low, the battery alarm LED onthe operator panel is lit, and the low--voltage battery alarm (system--035)is displayed on the teach pendant. When this alarm is displayed, replacethe battery as soon as possible. In general, the battery can be replacedwithin one or two weeks, however, this depends on the systemconfiguration.If the battery voltage gets lower, it becomes impossible to back up thecontent of the SRAM. Turning on the power to the in this state causessystem not to start and LED of seven segment on the Robot controller PCboard to be displayed “1” because the contents of memory are lost. Clearthe entire SRAM memory and reenter data after replacing the battery.Important data should be saved to the memory card or floppy diskbeforehand in case of emergency.When replacing the memory backup battery, do so while the robotcontroller is turned off in case of emergency.

NOTEIn a newly introduced robot, the battery is factory--installed.Battery replacement may, therefore, be needed within 4years after the introduction of the robot.

(1)Prepare a new lithium battery (ordering drawing number:A02B--0200--K102).

(2)Turn the robot controller on for about 30 seconds.(3)Turn the robot controller off.(4)Remove the old battery from the top of the Robot controller PC board.

First unlatch the battery, remove it from the battery holder, and detachits connector.

7.15REPLACINGBATTERY

7.15.1Battery for MemoryBackup (3 VDC)

Replacing the lithiumbattery


152

Battery latch

Lithium battery

Batteryconnector

(5)Remove the old battery, insert a new one into the battery holder, andattach the connector. Confirm that the battery is latched firmly.

WARNINGUsing other than the recommended battery may result in thebattery exploding.Replace the battery only with the specified battery(A02B--0200--K102).

CAUTIONComplete the steps (3) to (5) within 30 minutes.If the battery is left disconnected for a long time, thecontents of memory will be lost.To prevent possible data loss, it is recommended that therobot data such as programs and system variables bebacked up before battery replacement.

Dispose of the replaced battery as an industrial waste, according to thelaws and other rules in the country where the controller is installed andthose established by the municipality and other organizations that havejurisdiction over the area where the controller is installed.

III CONNECTION

B--81525EN--1/01 1. GENERALCONNECTIONS

155

1 GENERAL

This chapter describes the connection and the installation of the electricalinterface.

2. BLOCK DIAGRAM B--81525EN--1/01CONNECTIONS

156

2 BLOCK DIAGRAM

Following are the block diagrams of the electrical interface connection forR--J3iB Mate.

R--J3iB Mate controller

RobotcontrolP.C. board Operation

panel

Peripheral device

RS--232--CRS--422/485

Teach pendant

Emergency stop

Emergencystop unit

Powersupplyunit

Emergency stopP.C.board

(Note2)

Transformer

Fan

Fuse

MCC Servoamplifier

(Brake)

(RDI/RDO)

Power

Pulse coder

Robot

Cir-cuitpro-tec-tor

Cir-cuitpro-tec-tor Tr

ansf

orm

er

220, 380,415, 440,500VAC

NOTETranceformer is installed when the robot is for 6--axes brakespecification.

B--81525EN--1/01 3. CONNECTION DETAILSCONNECTIONS

157

3 CONNECTION DETAILS

CP8B

CP5

JRS12

PCMCIA

COP10A

CRM82

JD17

JD1A

JD1B

CRM79

CRM81

PCMCIA

EMGIN1, 2

SVOFF1, 2CP5B

CRS24EMGOUT11, 12

EMGOUT21, 22

CRS1

RS--232--C or RS--422/485

Robot controllerPC board

Battery

Emergencystop unit

Emergencystop circuit

Teach pendant

Servo amplifier

Mechanical unit

I/O Link (master)

I/O Link (slave : option)

Peripheral device

Peripheral device (option)

FENCE1, 2

3. CONNECTION DETAILS B--81525EN--1/01CONNECTIONS

158

When the stand--alone controller is used, an optional power cable can be specified.

A grounding stud is providedbeside the circuit protector.Connect the primary powerground wire to this stud. Usean M4 crimp terminal.

Circuit protectorTerminal is M4.

To primary power supply3Φ220/380/415/440/500VAC

Use the cable holders areprovided at these locations.(3 locations)

NOTEConnect the primary power cable to the circuit protector. Connect the primarypower ground wire to the grounding stud, located beside the circuit protector.

The power supply cables are optional.

3.1CONNECTING THEPOWER SUPPLYCABLE


159

Table 3.2 Types of FANUC I/O Links

No Name Drawing numberI/O Link

RemarksNo. Name Drawing numberMaster Slave

Remarks

1 Robot controller PC board A16B--3200--0450 f(*) f(*) Standard

NOTEThe I/O Link of the robot controller PC board is in the mastermode by default. The I/O Link can be used in the slavemode by changing the software parameter setting.

Refer to the operator’s manual for setting slave mode.

3.2FANUC I/O LINK


160

When the R--J3iB Mate control unit is used as the master of an I/O link(when R--J3iB Mate control the process I/O printed board)

R--J3iB Mate

JD1A JD4*Process I/Oprinted boord etc.

to other I/O link

*Note that the connector name differs fromthat of the standard FANUC I/O link.

JD1AJD1B

When the R--J3iB Mate control unit is used as a slave of the I/O link(when a CNC or PLC is used as the master of the I/O link)

CNC, PLC

JD1B

FANUC I/OUnit etc.

When the R--J3iB Mate control unit is used as the master and a slave of an I/O link

JD1B

FANUC I/OUnit etc.

JD1A

JD1B2

JD1B1 JD1A1

JD1A2

FANUC I/O Link connection unit

to other I/O link

*Note Switch by the software.

JD4*

JD1A

R--J3iB Mate

JD1A

R--J3iB Mate

CNC, PLC


161

Peel off the sheath of the shieldedcable, then ground the shield here.

1. Customer should be prepare this cable.2. Power off when it is connected.

When making a connection with a CNC via an I/O link, apply the following timing to turnthe power to the CNC and robot controller on/off:

a) Turn on the power to the slave units when or before turning on the master power.

b) If the power to the CNC or robot controller is turned off after the system has beenstarted, an I/O link error will occur. To reestablish normal connection via the I/O link,turn off the power to all units, then turn on the power as explained in a) above.

JD1A interface JD4(JD1B) interface

Note) When using an opticalI/O link adaptor, use +5V.

Note) When using an optical I/O linkadaptor, use +5V.

Cable connections should be made ac-cording to the system. The customer isrequested to ground the shield.

For other I/O link

JD1A

Control printed board

Earth plate

JD1B

I/O Link cable connection

11 0V 01 RXSLC1

12 0V 02 *RXSLC1

13 0V 03 TXSLC1

14 0V 04 *TXSLC1

15 0V 05

16 0V 06

17 07

18 (+5V) 08

19 09 (+5V)

20 (+5V) 10

11 0V 01 RXSLC2

12 0V 02 *RXSLC2

13 0V 03 TXSLC2

14 0V 04 *TXSLC2

15 0V 05

16 0V 06

17 07

18 (+5V) 08

19 09 (+5V)

20 (+5V) 10

(1)Twisted--pair cables should be used for pin pairs 1 and 2, and 3 and 4.

(2)Use unified shielding, and ground the shield on the CNC side.

3.3CONNECTING THEI/O LINK CABLE


162

Cable connection

Master

Robot controller PCBJD1A

RXSLC1 (1)

*RXSLC1 (2)

TXSLC1 (3)

*TXSLC1 (4)

0V (11)

0V (12)

0V (13)

0V (14)

0V (15)

0V (16)

I/O unit, etcJD1B

(1) SIN [RX]

(2) *SIN [*RX]

(3) SOUT [TX]

(4) *SOUT [*TX]

(11) 0V

(12) 0V

(13) 0V

(14) 0V

(15) 0V

(16) 0V

Slave

CNC, PLC etcJD1A

[RX] SIN (1)

[*RX] *SIN (2)

[TX] SOUT (3)

[*TX] *SOUT (4)

0V (11)

0V (12)

0V (13)

0V (14)

0V (15)

0V (16)

Robot controller PCBJD1B

(1) RXSLC2

(2) *RXSLC2

(3) TXSLC2

(4) *TXSLC2

(11) 0V

(12) 0V

(13) 0V

(14) 0V

(15) 0V

(16) 0V


163

CLOSEOPENSR2--1AUTO T1 T2

Dead man switch(Right)(Left)

Enable/Disable switch

SVOFF

Teach pendantEmergency stop button


Robot controllerP.C. board

Operation panelmode switch

Servo amplifier(αPSMR--1i)

Externalemergency stop

CRS1 24INCRT12

+24V

TBEB5EMGIN1

EMGIN2

FENCE1

FENCE2

SVOFF1

EMGOUT11

EMGOUT12

EMGOUT21

EMGOUT22

SVOFF2

JRS12

MODE1

MODE2

+24V0V

CX4 +24V

ESP

+24V

ESP

KA3--1

KA3--2

+24VKA4--2

KA4--10V +24V

KA2--2

KA2--1

KA6--1

KA6--20V

0V

CX3MCCOFF3

MCCOFF4RL1

CZ1

MCC(KM1)

CRS24

KM1--1

KM1--2

KM1--3

KM1--4

KM1--5

CRR78

KA5--2

KA5--1CRM83

0V

+24V

3φ200VAC

FENCE

OP--EMG

EX--EMG

MCCMON

AUTO T2T1

SR2--1

SR2--2

SR2--3

+24V

FUS3FUS4

Emergency stopbutton

(From CP5A)

Mode switch

SR2--2SR2--3 CLOSE

CLOSECLOSEOPEN

CLOSEOPENOPEN

safety net

3.4EMERGENCY STOPCIRCUIT

3.4.1Emergency StopCircuit Diagram


164

When the robot is shipped, EMGIN1, and EM-GIN2/SVOFF1 and SVOFF2/FENCE1 and FENCE2are connected by jumper wires. To enable externalemergency stop input, servo off input and fence inputfirst disconnect these jumper wires, then make thenecessary connections.External emergency stop input and fence input arereflected in the external emergency stop output, butservo off input is not reflected in the external emer-gency stop output..In order to prevent any problem caused by a wrongconnection, check the operation of the emergencystop switches on the teach pendant and operatorpanel after connecting the external emergency stopinput, servo off input and fence input.

EMGIN2

EMGIN1

SVOFF2

SVOFF1

EMGIN1EMGIN2SVOFF1SVOFF2

EMGOUT11EMGOUT12EMGOUT21EMGOUT22

TBEB5

Customer should prepare this cable

Cable holder

Emergency stop P.C. boardServo off input

External emergencystop input

FENCE2

FENCE1

Fence input

FENCE2FENCE1

FENCE1FENCE2EMGIN1EMGIN2SVOFF1SVOFF2

3.4.2External EmergencyStop Input


165

EMGIN1EMGIN2SVOFF1SVOFF2


TBEB5

Customer should prepare this cable

Cable holder


Externalemergency stop

An emergency stop button on the teach pen-dant, deadman’s switch an emergency stopbutton on the control unit door, and externalemergency stop input #1 are reflected in theexternal emergency stop output.

EMGOUT11

EMGOUT12

EMGOUT21

EMGOUT22

TPEmergencystop

OPEmergencystop

circuitSequencer etc. forperipheral device

FENCE2


FENCE1

3.4.3External EmergencyStop Output


166

LR Mate 100iB

CXA2A

JF1 (L)

JF2 (M)

CZ2 L

CZ2 M

COP10B COP10A

CXA2B CXA2A

JF1 (L)

JF2 (M)

JF3 (N)

CZ2 L

CZ2 M

CZ2 N

CZ1

CX1A CXA2A

CX3

CX4

COP10B

CXA2B CXA2A

PSM AMP1 AMP2

TB1

L+

L--

TB1

L+

L--

TB1

L+

L--

POWER SUPPLYMODULE

(αPSMR--1i)A06B--6115--H001

SERVO AMPLIFIERMODULE

(αSVM2--20/20i)A06B--6114--H205


(αSVM3--10/10/10i)A06B--6114--H302

from MCC

from circuitprotector

from emergencystop P.C.board

from robot controlP.C. board

to robot

Pulse coder

Motor power

LR Mate 200iB

CXA2A

JF1 (L)

JF2 (M)

CZ2 L

CZ2 M

COP10B COP10A

CXA2B CXA2A

JF1 (L)

JF2 (M)

JF3 (N)

CZ2 L

CZ2 M

CZ2 N

CZ1

CX1A CXA2A

CX3

CX4

COP10B

CXA2B CXA2A

PSM AMP1 AMP2

TB1

L+

L--

TB1

L+

L--

TB1

L+

L--

POWER SUPPLYMODULE

(αPSMR--1i)A06B--6115--H001


(αSVM3--10/10/10i)A06B--6114--H302

from MCC

from circuitprotector

from emergencystop P.C.board

from robot controlP.C. board

to robot

Pulse coder

Motor power

JF3 (N)

CZ2 N


(αSVM3--10/10/10i)A06B--6114--H302

3.5CONNECTION OFSERVO AMPLIFIER


167

CRM82

JF1--3

Power cable

to RMP

Signal cable

CZ2 L, M, NTBEB3

3.6CONNECTION OFROBOT


168

Emergency stop unit

CRS1

To teach pendant

Earth plate

Fig.3.7 Teach pendant cable

3.7CONNECTION OFTEACH PENDANTCABLE


169

Selection of RS--232--C or RS--422 interface need setting of software.Refer to the operator’s manual for details.

Communication port

Peripheral device

01 FG

02 TXD

03 RXD

04 RTS

05 CTS

06 DSR

07 0 V

08

09

10

11

12

13

14 (TX)

15 (*TX)

16 (RX)

17 (*RX)

18

19

20 DTR

21

22

23

24

25 +24E

Signals whose names are enclosed inparentheses are assigned to use theRS--422 interface. The numbers ofthe interface differ from those of thestandard RS--422 interface. Take thecaution when designing the interface.

3.8CONNECTION OFCABLE FORRS--232--C/RS--422


170

Table 3.9.1 Types of FANUC I/O Links

Peripheral device interface

No. Name Drawing number CRM79 CRM81 Remarksg

DI DO DI DO

1 Robot controller PC board A A16B--3200--0450 20 20 8 4 Standard

NOTEThe DI and DO signals of CRM79 and CRM81 includespecial signals.

Connecting a peripheral device (CRM79 or CRM81)

Grounding plateStrip off the sheathing of the shield cable andconnect the cable to the grounding plate.

CRM81

to peripheral device

CRM79


Fig.3.9.1 Connecting the peripheral device cable

3.9CONNECTING ACABLE TO APERIPHERALDEVICE

3.9.1Peripheral DeviceInterfaces CRM79 andCRM81


171

NOTESee the operator’s MANUAL for the detail information.

Turn off the controller when connecting the cable.

RobotcontrollerPCB

CNC

CRM79

CRM81

CRM79 interface (Specified signals are not allocated and the Robotis connected to CNC and PLC by a FANUC I/O Link cable.)

SDI101

SDI102

SDI103

SDI104

SDI105

SDI106

SDI107

SDI108

SDI109

SDI110

SDI111

SDI112

SDI113

SDI114

SDI115

SDI116

0 V

0 V

SDICOM1

SDICOM2

SDI117

SDI118

SDI119

SDI120

0 V

0 V

+24E

+24E

SDO101

SDO102

SDO103

SDO104

SDO105

SDO106

SDO107

SDO108

SDO109SDO110

SDO111

SDO112

SDO113

SDO114

SDO115

SDO116

+24E

+24E

Connector in cable sideHONDA TSUSHIN CO.,LTDConnector MR--50LMH(Male)

SDICOM1 and SDICOM2 are the signals used for selecting a common for SDI signals.To use the +24V common, connect SDICOM1 and SDICOM2 to 0V.To use the 0V common, connect SDICOM1 and SDICOM2 to +24V.SDICOM1→Selects a common for SDI101 to SDI108.SDICOM2→Selects a common for SDI109 to SDI120.

(Note) Maximum output current per one SDO signal is 70mA.

01

02

03

04

05

06

07

08

09

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

45

46

47

48

49

50

SDO120

SDO117

SDO118

SDO119

3.9.2When the Robot isConnected to the CNCby a Peripheral DeviceCable


172

CRM79 interface(standard allocation of specified signals andthe Robot is connected to the CNC and PLCby a peripheral device cable.)

01 SDI101

02 SDI102

03 SDI103

04 SDI104

05 SDI105

06 SDI106

07 SDI107

08 SDI108

09 *HOLD

10 RESET

11 START

12 ENBL

13 PNS1

14 PNS2

15 PNS3

16 PNS4

17 0 V

18 0 V

19 SDICOM1

20 SDICOM2

21

22 SDI117

23 SDI118

24 SDI119

25 SDI120

26

27

28

29 0 V

30 0 V

31 +24E

32 +24E

33 SDO101

34 SDO102

35 SDO103

36 SDO104

37 SDO105

38 SDO106

39 SDO107

40 SDO108

41 SDO109

42 SDO110

43 SDO111

44 SDO112

45 CMDENBL

46 FAULT

47 BATALM

48 BUSY

49 +24E

50 +24E

Connector in cable sideHONDA TSUUSHIN CO.,LTDConnector MR--50LMH (Male)

SDICOM1 and SDICOM2 signal are common selection signal for SDI.When 24 V common is used, connect to 0V.When 0V common is used, connect to +24VSDICOM1”Selects a common for SDI101 to SDI108.SDICOM2”Selects a common for *HOLD, RESET,

START, ENBL, PNS1 to PNS4, and SDI117 to SDI120.

SDO120

SDO117

SDO118

SDO119

NOTE1 Maximum output current for one SDO signal is 70mA.2 The common (selected with SDICOM2) for a dedicated

signal should ideally be the +24V common, but the 0Vcommon can also be used.

3 Allocation of the specified signals can be changed from theteach pendant.


173

In case +24V common at the peripheral device side. (Specified signals are not allocated)

Control unit (peripheral device interface : CRM79) Peripheral device

SDI101 RVCRM79 (1)

CRM79 (31,32,49,50)

Connector pin No+24E

SDICOM1CRM79 (19)

SDI120CRM79 (25)

SDICOM2CRM79 (20)

CRM79 (17,18,29,30)

0V

SDI102CRM79 (2)

SDI103CRM79 (3)

SDI104CRM79 (4)

SDI105CRM79 (5)

SDI106CRM79 (6)

SDI107CRM79 (7)

SDI108CRM79 (8)

SDI109CRM79 (9)

SDI110CRM79 (10)

SDI111CRM79 (11)

SDI112CRM79 (12)

SDI113CRM79 (13)

SDI114CRM79 (14)

SDI115CRM79 (15)

SDI116CRM79 (16)

SDI117CRM79 (22)

SDI118CRM79 (23)

SDI119CRM79 (24)

3.3kRV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

receiver circuit

Fig.3.9.2 (a) Peripheral device control interface : CRM79 (Input signal, +24V common)


174

In case 0V common at the peripheral device side. (Specified signals are not allocated)

SDI101 RVCRM79 (1)

SDICOM1CRM79 (19)

SDI120CRM79 (25)

SDICOM2CRM79 (20)

CRM79 (17,18,29,30)

0V

SDI102CRM79 (2)

SDI103CRM79 (3)

SDI104CRM79 (4)

SDI105CRM79 (5)

SDI106CRM79 (6)

SDI107CRM79 (7)

SDI108CRM79 (8)

SDI109CRM79 (9)

SDI110CRM79 (10)

SDI111CRM79 (11)

SDI112CRM79 (12)

SDI113CRM79 (13)

SDI114CRM79 (14)

SDI115CRM79 (15)

SDI116CRM79 (16)

SDI117CRM79 (22)

SDI118CRM79 (23)

SDI119CRM79 (24)

3.3k


CRM79 (31,32,49,50)


receiver circuit

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

Fig.3.9.2 (b) Peripheral device control interface : CRM79 (Input signal, 0V common)


175

(Specified signals are not allocated)

SDO101 DVCRM79 (33)

CRM79 (17,18,29,30)

0V

LOAD

RELAY

SDO102 LOADCRM79 (34)

SDO103CRM79 (35)

SDO104CRM79 (36)

SDO105CRM79 (37)

SDO106CRM79 (38)

SDO107CRM79 (39)

SDO108CRM79 (40)

SDO109CRM79 (41)

SDO110CRM79 (42)

SDO111CRM79 (43)

SDO112CRM79 (44)

SDO113CRM79 (45)

SDO114CRM79 (46)

SDO115CRM79 (47)

SDO116CRM79 (48)

SDO117CRM79 (26)

SDO118CRM79 (27)

SDO119CRM79 (28)

SDO120CRM79 (21)

0V +24V+24V reguratedpower supply


Connector pin NoDriver circuit

Max. current per SDO is 70mA.

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

Fig.3.9.2 (c) Peripheral device control interface : CRM79 (Output signal)


176

In case +24V common at the peripheral device side. (Specified signals are allocated)


SDI101 RVCRM79 (1)

CRM79 (31,32,49,50)


SDICOM1CRM79 (19)

SDI120CRM79 (25)

SDICOM2CRM79 (20)

CRM79 (17,18,29,30)

0V

SDI102CRM79 (2)

SDI103CRM79 (3)

SDI104CRM79 (4)

SDI105CRM79 (5)

SDI106CRM79 (6)

SDI107CRM79 (7)

SDI108CRM79 (8)

SDI109CRM79 (9)

SDI110CRM79 (10)

SDI111CRM79 (11)

SDI112CRM79 (12)

SDI113CRM79 (13)

SDI114CRM79 (14)

SDI115CRM79 (15)

SDI116CRM79 (16)

SDI117CRM79 (22)

SDI118CRM79 (23)

SDI119CRM79 (24)

3.3kRV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

receiver circuit

Fig.3.9.2 (d) Peripheral device control interface : CRM79 (Input signal, +24V common)


177

In case 0V common at the peripheral device side. (Specified signals are allocated)

SDI101 RVCRM79 (1)

SDICOM1CRM79 (19)

SDI120CRM79 (25)

SDICOM2CRM79 (20)

CRM79 (17,18,29,30)

0V

SDI102CRM79 (2)

SDI103CRM79 (3)

SDI104CRM79 (4)

SDI105CRM79 (5)

SDI106CRM79 (6)

SDI107CRM79 (7)

SDI108CRM79 (8)

SDI109CRM79 (9)

SDI110CRM79 (10)

SDI111CRM79 (11)

SDI112CRM79 (12)

SDI113CRM79 (13)

SDI114CRM79 (14)

SDI115CRM79 (15)

SDI116CRM79 (16)

SDI117CRM79 (22)

SDI118CRM79 (23)

SDI119CRM79 (24)

3.3k


CRM79 (31,32,49,50)


receiver circuit

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

RV

Fig.3.9.2 (e) Peripheral device control interface : CRM79 (Input signal, 0V common)


178

(Specified signals are allocated)

SDO101 DVCRM79 (33)

CRM79 (17,18,29,30)

0V

LOAD

RELAY

SDO102 LOADCRM79 (34)

SDO103CRM79 (35)

SDO104CRM79 (36)

SDO105CRM79 (37)

SDO106CRM79 (38)

SDO107CRM79 (39)

SDO108CRM79 (40)

SDO109CRM79 (41)

SDO110CRM79 (42)

SDO111CRM79 (43)

SDO112CRM79 (44)

SDO113CRM79 (45)

SDO114CRM79 (46)

SDO115CRM79 (47)

SDO116CRM79 (48)

SDO117CRM79 (26)

SDO118CRM79 (27)

SDO119CRM79 (28)

SDO120CRM79 (21)

0V +24V+24V reguratedpower supply


Connector pin NoDriver circuit


DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

DV

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

LOAD

Fig.3.9.2 (f) Peripheral device control interface : CRM79 (Output signal)


179

CRM81 interface(When a special signal is not allocated; when CNC andPLC areconnectedby an I/O Link cable)

A B

01 SDI81 SDI82

02 SDI83 SDI84

03 SDI85 SDI86

04 SDI87 SDI88

05 SDICOM

06

07 SDO81 SDO82

08 SDO83 SDO84

09 0V

10 +24V 0V

SDICOM1 is a common signal that can be used either as an SDI or specialsignal.

+24 V common: Connected to 0 V0 V common: Connected to +24 V

SDICOM → Selects a common for SDI81 to SDI88.

CAUTIONThe maximum output current of each SDO or special signalis 70 mA.

Cable--side connectorYAMAICHI ELECTRICITY

ConnectorHousing -- UFS--20B--04Contact -- Contact 66 type

(UFS contact)


180

In case +24V common at the peripheral device side.

SDI81CRM81 (A1)

CRM81 (A10)

SDICOMCRM81 (A5)

SDI88CRM81 (B5)

CRM81 (B9,B10)

0V

SDI82CRM81 (B1)

SDI83CRM81 (A2)

SDI84CRM81 (B2)

SDI85CRM81 (A3)

SDI86CRM81 (B3)

SDI87CRM81 (A4)



RV3.3k

receiver circuit

RV

RV

RV

RV

RV

RV

RV

RV

Fig.3.9.2 (g) Peripheral device control interface : CRM81 (Input signal, +24V common)


181

In case 0V common at the peripheral device side.

SDI81CRM81 (A1)

CRM81 (A10)

SDICOMCRM81 (A5)

SDI88CRM81 (B5)

CRM81 (B9,B10)

0V

SDI82CRM81 (B1)

SDI83CRM81 (A2)

SDI84CRM81 (B2)

SDI85CRM81 (A3)

SDI86CRM81 (B3)

SDI87CRM81 (A4)



receiver circuit

RV3.3k

RV

RV

RV

RV

RV

RV

RV

RV

Fig.3.9.2 (h) Peripheral device control interface : CRM81 (Input signal, 0V common)

SDO81

CRM81 (A7)

CRM81 (B9,B10)

SDO82 LOADCRM81 (B7)

SDO83CRM81 (A8)

SDO84CRM81 (B8)

0V +24V

DVRELAY


Connector pin NoDriver circuit LOAD

DV

DV

DV

LOAD

LOAD

0V

+24V reguratedpower supply


Fig.3.9.2 (i) Peripheral device control interface : CRM81 (Output signal)


182

This section describes the specifications of the digital I/O signalsinterfaced with the peripheral device and end effector.

Connection example

Protective resistance

Lamp

70 mAor less

0V

+24V

70 mAor less

0V

+24V

Spark killer diode

0V

0V

D Electrical specificationsRated voltage : 24 VDCMaximum applied voltage : 30 VDCMaximum load current : 70.mATransistor type : Open collector NPNSaturation voltage at connection : 1.0 V (approx.)

D Spark killer diodeRated peak reverse voltage : 100 V or moreRated effective forward current : 1 A or more

D Notes on useDo not use the +24 V power supply of the robot.When loading a relay, solenoid, and so on directly, connect them inparallel with diodes for preventing back electromotive force.If a load causing a surge current such as turning on LED is connected,use a protective resistance.

D Applicable signalOutput signal of peripheral device interface CRM79, CRM81 :

SDO101 to SDO120 (CRM79)SDO81 to SDO84 (CRM81)

3.9.3Digital I/O SignalSpecifications

3.9.3.1Peripheral deviceinterface CRM 79 andCRM 81

D Output signal regulation


183

Connection example

3.3 kΩ

RV

SDICOM

+24V

0V

RV

SDI n

Example of+24V common connection

D Electrical specifications of the receiverType : Grounded voltage receiverRated input voltage : Contact close :+20 V to +28 V

Contact open :0 V to +4 VMaximum applied input voltage: +28 VDCInput impedance : 3.3 kΩ (approx.)Response time : 5 ms to 20 ms

D Specifications of the peripheral device contactRated contact capacity : 30 VDC, 50 mA or moreInput signal width : 200 ms or more (on/off)Chattering time : 5 ms or lessClosed circuit resistance : 100Ω or lessOpened circuit resistance : 100 kΩ or more

(Signal)(Signal)

TCTC

TBTBTB

Peripheral devicecontact signal

Robot receiver signal

TB ; Chattering 5 ms or lessTC ; 5 to 20 ms

D Note on useApply the +24 V power of the robot to the receiver.However, the above signal regulations must be satisfied at therobot receiver.

D Applicable signalInput signal of peripheral device interface CRM79, CRM81 :

SDO101 to SDO120 (CRM79)SDO81 to SDO84 (CRM81)

D Input signal regulation


184

The figure below shows the connector for peripheral device cable.

Symbol Name

1 Connector cover

2 Cable clamp screw

3 Connector clamp spring

4 Connector clamp screw

5 Connector 50 pins (male) MR50MH

Connector Applicable Dimensions RemarkConnectorspecification

Applicableinterface A (B) C (D) Honda Tsushin

MR50LMH CRM79 67.9 73.5 44.8 18Honda TsushinKogyo 50 pins

Fig.3.9.4 (a) Peripheral Device Cable Connector (CRM79 : Honda Tsushin Kogyo)

3.9.4Peripheral DeviceCable Connector


185

Connector Applicable DimensionsRemarkConnector

specificationApplicable

interface A CRemark

UFS--20B--04

CRM81

29.98 22.86 YAMAICHI ELECTRONICS(Housing)

Contact 66 typeCRM81

YAMAICHI ELECTRONICS(Contact)

Applicable cable : AWG#28 (7/0.12), AWG#26 (19/0.1), AWG#24 (19/0.12), (7/0.18)

Fig.3.9.4 (b) Peripheral Device Cable Connector (CRM81 : YAMAICHI ELECTRONICS)

Connect a peripheral device using a completely shielded, heavilyprotected cable conforming to the specifications in Table 3.9.5.Allow an extra 1.5m for routing the cable in the control unit.The maximum cable length is 30m.

Table 3.9.5 Recommended cable (For peripheral device connection)

Wire specificationsConductor

SheathEffective Electrical characteristics

Number ofwires

Wire specifications(FANUC

specifications)Diameter

(mm)Configura-

tion

Sheaththickness

(mm)

Effectiveoutside

diameter(mm)

Conductorresistance

(Ω/km)

Allowablecurrent (A)

50 A66L--0001--0042 φ1.05 7/0.18AWG24

1.5 φ12.5 106 1.6

20 A66L--0001--0041 φ1.05 7/0.18AWG24

1.5 φ10.5 106 1.6

3.9.5Recommended Cables

3.562.54

AB

2.54

6.0

14.314.5


186

Table 3.10.1 Types of end effector interfaces

No Name Drawing numberEnd effector interface

RemarksNo. Name Drawing numberDI DO

Remarks

1 Robot controller PC board A A16B--3200--0450 6 6 Standard

NOTEEither RDI6 or *PPABN is selected in the software.

1 RDI1 7 *HBK2 RDI2 8 +24E3 RDI3 9 +24E4 RDI4 10 +24E5 RDI5 11 0V

6 RDI6(*PPABN)

12 RDICOM

EE

Mechanical unit

End effecter

NOTERDO1 to RDO6 are used as the signals to turn on or offsolenoid valves. The end effector can use the RDI signalsand *HBK signal. For RDO signals, refer to themaintenance manual of the mechanical unit.

3.10END EFFECTORINTERFACE

3.10.1Connecting theMechanical Unit andEnd Effector


187

End effector

RDI1 RVEE (1)

EE (8,8,10)Connector pin No.+24E

Receiver circuit

RDICOMEE (12)

EE (11)

0V

RDI2EE (2)

RDI3EE (3)

RDI4EE (4)

RDI5EE (5)

RDI6(*PPABN)

EE (6)

3.3k

Mechanical unit (end effector interface)

RV

RV

RV

RV

RV

RV

Fig.3.10.1 (a) End effector interface (+24V common)

End effector

RDI1 RVEE (1)

EE (8,8,10)Connector pin No.+24E

Receiver circuit

RDICOMEE (12)

EE (11)

0V

RDI2EE (2)

RDI3EE (3)

RDI4EE (4)

RDI5EE (5)

RDI6(*PPABN)

EE (6)

3.3k

Mechanical unit (end effector interface)

RV

RV

RV

RV

RV

RV

Fig.3.10.1 (b) End effector interface (0V common)


188

Connection example

3.3 kΩ

RV

RDICOM

+24V

0V

RV

RDI n

+24V commonconnection example

Electrical specifications of the receiver

Type : Grounded voltage receiverRated input voltage : Contact close

: +20 V to +28 VContact open

: 0 V to +4 VMaximum applied input voltage : +28 VDCInput impedance : 3.3 kΩ (approx.)Response time : 5 ms to 20 ms

Specifications of the peripheral device contact

Rated contact capacity : 30 VDC, 50 mA or moreInput signal width : 200 ms or more (on/off)Chattering time : 5 ms or lessClosed circuit resistance : 100 Ω or lessOpened circuit resistance : 100 kΩ or more

(Signal)(Signal)

TCTC

TBTBTB

Peripheral devicecontact signal

Robot receiver signalTB ; Chattering 5 ms or lessTC ; 5 to 20 ms

Note on use

Apply the +24 V power at the robot to the receiver.However, the above signal specifications must be satisfied at therobot receiver.

Applicable signals

Input signals of end effecter control interfaceAdditional I/O PCB CRW6 input signal WDI1 to WDI8RDI 1 to 6, *HBK, *PPABN (Switch RDI6 by software)

3.10.2Digital I/O SignalSpecifications of EndEffecter ControlInterface


189

In this manual the treatment for the shielded cable is shown on severalpages. Partly cut off the shielded cable to expose the shield jacket, andfasten the jacket to the shield plate with a clamp to protect against noise.(In case of stand--alone type a shield plate is installed in the controller.)

Fig.3.11 Shielded cable treatment

3.11TREATMENT FORTHE SHIELDEDCABLE

CONNECTION4. TRANSPORTATION AND

INSTALLATION B--81525EN--1/01

190

4 TRANSPORTATION AND INSTALLATION

CONNECTIONB--81525EN--1/014. TRANSPORTATION AND

INSTALLATION

191

The control unit should be transported by a crane. Attach a sling to eyebolts at the top of the control unit.

Fig.4.1 Transportation

Installation areaWhen the control unit is installed, allow the space for maintenance shownin the following figure.

When the pluralcontroller isinstalled.

Control unit Control unitControl unit

Fig.4.2 Installation

4.1TRANSPORTATION

4.2INSTALLATION



192

Four M10 weld nuts (4 pcs)The unit is shipped with the M10 boltsscrewed to the weld nuts as 10--mm feet.After the M10 bolts are removed, theseweld nuts can be used to secure thecontrol unit.

Fig.4.3 External drawing of robot controller

4.3EXTERNALCONTROLLERDIMENSIONS

CONNECTIONB--81525EN--1/014. TRANSPORTATION AND

INSTALLATION

193

Item Specifications/condition

Transformer 50Hz/60Hz;220/380/415/440/500VAC,+10%, --15%

50/60Hz ± 1Hz, 3--phase

Input power supply capacity 1 kVA (LR Mate 100iB)1.2 kVA (LR Mate 200iB)

Average power consumption 0.4 kW (LR Mate 100iB)0.5 kW (LR Mate 200iB)

Permissible ambient temper-ature

0 to 45_C during operation, and --20 to 60 Cduring shipment and storage with a tempera-ture coefficient of 1.1_C/min.

Permissible ambient humid-ity

Relative humidity: 30% to 95%, non--condens-ing.

Surrounding gas An additional protective provision is neces-sary if the machine is installed in an environ-ment in which there are relatively largeamounts of contaminants (dust, dielectricfluid, organic solvent, acid, corrosive gas,and/or salt).

Vibration 0.5 G or less. When using the robot in a loca-tion subject to serious vibration, consult withyour FANUC sales representative.

Altitude Not higher than 1,000 m above sea level

Ionized and nonionized radi-ations

A shielding provision is necessary if themachine is installed in an environment inwhich it is exposed to radiations (microwave,ultraviolet rays, laser beams, and/or X--rays).

Weight of control unit Approx. 55kg

Adjust and check according to following procedure at installation.

No. Description

1 Visually check the inside and outside of the control unit.

2 Check if the screwed terminal is connected properly.

3 Check that the connectors and printed circuit boards are inserted cor-rectly.

4 Connect control unit and mechanical unit cables.

5 Turn the breaker off and connect the input power cable.

6 Check the input power voltagage.

7 Press the EMERGENCY STOP button on the operator’s panel andturn the power on. Check the output voltage.

8 Check the interface signals between control unit and robot mechanicalunit.

9 Check the parameters. If necessary, set them.

10 Release the EMERGENCY STOP button on the operator’s panel.Turn the power on.

11 Check the movement along each axis in the manual jog mode.

12 Check the end effector interface signals.

13 Check the peripheral device control interface signals.

4.4INSTALLATIONCONDITION

4.5ADJUSTMENT ANDCHECKS ATINSTALLATION



194

An overtravel and emergency stop occur when the robot is operated forthe first time after it is installed and the mechanical and control units arewired. This section describes how to reset the overtrvel and emergencystop.Remove the red plate fastening the swiveling axis beforehand.The J2 and J3 axes are pressed against the hard stops at shipment.Therefore, an overtravel alarm occurs when the power is turned on afterinstallation.

(1) Press the [MENUS] key on the teach pendant.

(2) Select [Next].

(3) Select [SETUP].

(4) Press F1 [TYPE].

(5) Select [Config] to disable or enable Hand Break.

Hand break

State Hand break HBK (*1) HBK detection Robot operation Message

1 Enabled CLOSE Detected Possible Not provided

2 Enabled OPEN Detected Impossible SERVO 6

3 Disabled CLOSE Detected (*2) Possible Not provided

4 Disabled OPEN Not detected Possible SERVO 300 at cold start

NOTE1 Robot end effector connector

2 When the HBK circuit is closed, the HBK detection isenabled.If the HBK state changes from close to open, the SERVO300 or SERVO 302 alarm occurs, stopping the robot.

3 If the power is turned off and on in the state describedabove, the system enters state 4, releasing the alarm.

CLOSE OPEN24V

*HBK

24V

*HBK

4.6NOTE ATINSTALLATION

4.7DISABLING HANDBREAK

APPENDIX

B--81525EN--1/01 A. TOTAL CONNECTION DIAGRAMAPPENDIX

197

A TOTAL CONNECTION DIAGRAM

A. TOTAL CONNECTION DIAGRAM B--81525EN--1/01APPENDIX

198

Fig.A (a) Total connection diagram


199


200

Fig.A (b) Transformer


201


202

Fig.A (c) Emergency stop circuit diagram (LR Mate 100iB)


203


204

Fig.A (d) Emergency stop circuit diagram (LR Mate 200iB)


205


206

Fig.A (e) Robot controller P.C. board, emergency stop P.C. board connector interface


207

Fig.A (f) Servo amplifier, robot mechanical unit connector interface

B--81525EN--1/01APPENDIXB. PERIPHERAL INTERFACE

208

B PERIPHERAL INTERFACE

Peripheral I/O (UI/UO) are a group of specialized signals whose usage isdecided by the system. These signals are connected with a remotecontroller and the peripheral devices via the following interfaces and I/Olinks and they are used to control the robot from the outside.

D The JD1A interface (The process I/O PC board, the I/O Unit MODELA and the MODEL B are connected as the slave of I/O link to R--J3iBMate.) (on master mode)

D The JD1B interface (CNC and PLC are connected as a master of I/Olink to R--J3iB Mate.) (on slave mode)

D CRM9 interfaceRefer to the operator’s MANUAL for detail informations.

B--81525EN--1/01 APPENDIX B. PERIPHERAL INTERFACE

209

The tables below list the special signals of the R--J3iB Mate robotcontroller.

Input signals (See Subsection B.2.1.)

Signal Description

*HOLDRESETSTARTENBLPNS1PNS2PNS3PNS4

Temporary stopAlarm releaseCycle startEnableProgram select (*1)Program select (*1)Program select (*1)Program select (*1)

NOTEPNS (program select input) (optional)

Output signals (See Subsection B.2.1.)

Signal Description

CMDENBLFAULTBATALMBUSY

Input acceptableAlarmBattery alarmBusy

B.1SIGNAL TYPES


210

Fellowing is each input signal.

The remote controller uses the hold signal to halt the robot. Because*HOLD input signal is a inverted signal, normally set the signal on. Whenthe signal goes off, the following is executed:

D The robot is decelerated until its stops, then the program execution ishalted.

D If ENABLED is specified at “Break on hold” on the general itemsetting screen, the robot is stopped, an alarm is generated, and theservo power is turned off. (Standard setting: DISABLED)

The RESET signal cancels an alarm. If the servo power is off, the RESETsignal turns on the servo power. The alarm output is not canceled until theservo power is turned on. The alarm is canceled at the instant this signalfalls in default setting.

D If TRUE is specified at “CSTOPI for ABORT” on the systemconfiguration screen, the RESET signal resets an alarm and aborts thecurrently selected program. (Standard setting: FALSE)

D To have alarms reset the instant the RESET signal rises, it is necessaryto specify RISE at “Detect FAULT RESET signal” on the systemconfiguration screen. (Standard setting: FALL)

The START signal has two functions. It can select or collate a programand start the program.

D When the START signal goes high, PNS1 to PNS4 are read and thecorresponding program is selected or collated. Whether is program isselected or collated is specified by the setting of system variable$SHELL_CFG.$NUM_RSR [1]. (See the description of signalsPNS1 to PNS4.)

D When the START signal goes low, the current program is started fromthe line at which the cursor is placed (current line).

D If TRUE is specified at “START for CONTINUE only” on the systemconfiguration screen, only a program on hold can be started. (Standardsetting: FALSE)

The ENBL signal allows the robot to be moved and places the robot in theready state. When the ENBL signal is off, the system inhibits a jog feedof the robot and activation of a program including a motion (group). Aprogram which is being executed is halted when the ENBL signal is setoff.

NOTEWhen the ENBL signal is not monitored, strap the signalwith the ground.

B.2I/O SIGNALS

B.2.1Input Signals

Hold input signals,*HOLD, UI [ 1 ]

Fault reset input signal,RESET, UI [ 2 ]

Start input signal,START, UI [ 3 ] (validatedin the remote state)

Enable input signal,ENBL, UI [ 4 ]


211

A program number selection signal has two functions.When the START signal goes on, PNS1 to PNS4 are read and thecorresponding program is selected or collated. Whether the program isselected or collated is specified by the setting of system variable$SHELL_CFG.$NUM_RSR [1].

D In the program end state, a program is selected or collated accordingto the state (0 or 1) of the PNS signals. The current line of the selectedor collated program is set to 1.

- Type 1 (when $SHELL_CFG.$NUM_RSR [1] is set to 0)The program specified by the PNS signals is selected.

- Type 2 (when $SHELL_CFG.$NUM_RSR [1] is set to 1)The program specified by the PNS signals is collated with thecurrent program. If the programs do not agree with each other, anerror occurs.

D If all PNS signals are low in the program end state, the current programis executed from the current line. If no programs are selected, an erroroccurs.

D A halted program can be resumed only when all PNS signals are setoff. Otherwise, an error occurs.

D While a program is being executed, the PNS signals are ignored.

Fellowing are peripheral device interface output signals.

The CMDENBL signal is output when the following conditions aresatisfied. The CMDENBL signal indicates that the remote controller canstart a program including a motion (group).

D The remote conditions are satisfied.D The ready conditions are satisfied.

D The continuous operation mode is selected (the single step mode isdisabled).

The FAULT signal is output when an alarm occurs in the system. TheRESET signal cancels the alarm. If a warning (WARN alarm) occurs, theFAULT signal is not output.

The BATALM signal indicates that the voltage of the battery forsupporting the memory has dropped. Replace the battery while keepingthe power of the controller on.

To have the BATALM signal generated also when the BZAL/BLALalarmoccurs, it is necessary to set the $BLAL_OUT.$BATALM_OR systemvariable. It is also possible to have the specified SDO output when theBZAL/BLAL alarm occurs.

The BUSY signal is output while a program is being executed. The BUSYsignal is not output while a program is being halted.

Program numberselection signals, PNS1to PNS4, UI [ 5 to 8 ](validated in the remotestate)

B.2.2Output signals

Command enable outputsignal, CMDENBL,UO [ 1 ]

Fault output signal,FAULT, UO [ 2 ]

Battery alarm outputsignal, BATALM, UO [ 3 ]

Busy output signal,BUSY, UO [ 4 ]


212

This section describes the external specifications of digital and analoginput/output in the R--J3iB Mate controller.

The R--J3iB Mate controller can use up to 512 digital input and outputpoints or an equivalent number of analog input and output points. Oneanalog input/output point uses the resources equivalent to those used by16 digital I/O points. The R--J3iB Mate can use a total of up to 512 I/Opoints.

The R--J3iB Mate controller can use the following I/O hardware.- Process I/O printed circuit board- I/O unit model A

The process I/O printed circuit board and the I/O unit model A can be usedtogether.

B.3SPECIFICATIONS OFDIGITALINPUT/OUTPUT

B.3.1Overview

B.3.2Input/Output HardwareUsable in the R-J3iBMate Controller


213

(1) RDI/RDOThese are signals sent to the connector at the wrist of the robot.They cannot be assigned (redefined) and are fixed.The standard format is six inputs and six outputs. The number ofpoints that can be used for the connector at the wrist depends on theindividual robot.

(2) SDI/SDOThe signal No. that is determined at hardware can be changed bysoftware operation.

(3) Analog I/OAn analog I/O signal can access the analog I/O port (optional) on theprocess I/O printed circuit board or the I/O port on the analog I/Omodule (used together with the I/O unit model A).It reads and writes the digital value converted from the analog valueof the I/O voltage. It means that the value does not always representthe real I/O voltage.

(4) Group I/OGroup I/O is a function which can input or output multiple DI/DOsignals as binary codes.Any number of continuous signals of up to 16 bits can be set for itsuse.It can be set in the menu DETAILS on the group I/O screen.

B.3.3SoftwareSpecifications

C. OPTICAL FIBER CABLE B--81525EN--1/01APPENDIX

214

C OPTICAL FIBER CABLE

The R--J3iB Mate uses fiber optic cables for communication between therobot controller PC board and servo amplifier module and between theservo amplifier module and servo amplifier module. Observe thefollowing cautions when handling these fiber optic cables.

(1) Protection during storageWhen the electrical/optical conversion module (mounted on theprinted) circuit board and the fiber optic cable are not in use, theirmating surfaces must be protected with the lid and caps with whichthey are supplied. If left uncovered, the mating surfaces are likely tobecome dirty, possibly resulting in a poor cable connection.

Electrical/optical conversion module Lid

Fiber optic cable Fiber opticcable caps

Fig.C (a) Protection of electrical/optical conversion module and fiberoptic cable (when not in use)

B--81525EN--1/01 C. OPTICAL FIBER CABLEAPPENDIX

215

(2) Fiber optic cableD Grasp the optical connector firmly when connecting or

disconnecting the cable. Do not pull on the fiber optic cord itself.(The maximum tensile strength between the fiber cord andconnector is 2 kg. Applying greater force to the cord is likely tocause the connector to come off, making the cable unusable.)Fiber optic cord diameter : 2.2 mm × 2 cordsTensile strength : Fiber optic cord :7 kg per cord

Between fiber optic cord and connector : 2 kgMinimum bending radius of fiber optic cord :25 mmFlame resistance : Equivalent to UL VW--1Operating temperature : --20 to 70°C

60 max.

8.2

21

6.7 19 max. 35typ.

Code Bush Reinforced cover

Fig.C (b) External dimensions of external optical cable Unit : mm

D Afler it is connected, the optical connector is automatically lockedby the lock levers on its top. To remove the connector, release thelock levers and pull the connector.

D Although optical connectors cannot be connected in other than thecorrect orientation, always take note of the connector’s orientationbefore making the connection.

D Take care to keep both parts of the optical connector (cable side andPCB side) clean. If they become dirty, wipe them with tissue paperor absorbent cotton to remove dirt. The tissue paper or absorbentcotton may be moistened with ethyl alcohol. Do not use anyorganic solvent other than ethyl alcohol.

D Do not clamp the uncovered portion of the cable with a nylon band.

IndexB--81525EN--1/01

i--1

[A]Adjustment and Checks at Installation, 193

Alarm Occurrence Screen, 30

[B]Backplane PC Board (A20B--2003--0330), 116

Battery for Memory Backup (3 VDC), 151

Block Diagram, 156

Block Diagrams of the Power Supply, 123

[C]Checking the Power Supply Module, 124

Checking the Power Supply Unit, 124

Circuit Diagram of Emergency Stop, 163

Component Functions, 24

Configuration, 20

Connecting a Cable to a Peripheral Device, 170

Connecting the Mechanical Unit and End Effector,186

Connection Details, 157

Connection of Cable for RS--232--C/RS--422, 169

Connection of I/O Link Cable, 161

Connection of Power Supply Cable, 158

Connection of Robot, 167

Connection of Teach Pendant Cable, 168

Coonection of Servo Amplifier, 166

[D]Digital I/O Signal Specifications, 182

Digital I/O Signal Specifications of End Effecter Con-trol Interface, 188

Disabling Hand Break, 194

[E]Emergency Stop Circuit, 163

Emergency Stop PC Board (A20B--1008--0022,--0023), 115

End Effector Interface, 186

External Controller Dimensions, 192

External Emergency Stop Input, 164

External Emergency Stop Output, 165

External View of the Controller, 21

[F]FANUC I/O Link, 159

[I]I/O Signals, 210

Initial Screen Remains on the Teach Pendant, 29

Input Signals, 210

Input/Output Hardware Usable in the R--J3iB MateController, 212

Installation, 191

Installation Condition, 193

[L]LED of Power Supply Module, 120

LED of Servo Amplifier, 120

LED of Servo Amplifier Module, 121

[M]Manual Operation Impossible, 108

Mastering, 34

[N]Note at Installation, 194

[O]Operator Safety, 4, 6

Optical Fiber Cable, 214

Outline Drawings, 118

Output signals, 211

[P]Peripheral Device Cable Connector, 184

Peripheral device interface CRM 79 and CRM 81, 182

Peripheral Device Interfaces CRM79 and CRM81,170

Index B--81525EN--1/01

i--2

Peripheral interface, 208

Position Deviation Found in Return to the ReferencePosition (Positioning), 106

Power Cannot be Turned On, 27

Power Supply Module PSM (A06B--6115--H001), 118

Precautions for Mechanism, 10

Precautions for Mechanisms, 11

Precautions in Operation, 11

Precautions in Programming, 10, 11, 12

Preventive Maintenance, 25

Printed Circuit Boards, 110

[R]Recommended Cables, 185

Replacing a Fuse, 146

Replacing a Fuse on the Emergency Stop PC Board,147

Replacing a Fuse on the Robot Controller PC Board,146

Replacing a Relay, 150

Replacing a Relay on the Emergency Stop PC Board,150

Replacing a Unit, 126

Replacing Battery, 151

Replacing Cards and Modules on the Robot ControllerPC Board, 131

Replacing Servo Amplifiers, 139

Replacing the Backplane Board (Unit), 128

Replacing the Brake Power Transformer, 135

Replacing the Control Section Fan Motor, 141

Replacing the Door Fan Unit and Heat Exchanger,143

Replacing the Emergency Stop PC Board, 130

Replacing the Emergency Stop Unit, 137

Replacing the Fan Motor of the Servo Amplifier Con-trol Unit, 142

Replacing the Fuse on the Power Supply Module, 148

Replacing the Fuse on the Servo Amplifier Module,149

Replacing the Magnetic Contactor, 138

Replacing the Operator Panel, 144

Replacing the Power Supply Unit, 145

Replacing the Printed--Circuit Boards, 127

Replacing the Robot Controller PC Board andPrinted--Circuit Boards on the Backplane Unit, 129

Replacing the Teach Pendant, 140

Replacing the Transformer, 135

Robot Controller PC Board (A16B--3200--0450), 111

[S]Safety During Maintenance, 9

Safety in Maintenance, 13

Safety of the End Effector, 12

Safety of the Robot Mechanism, 11

Safety of the Teach Pendant Operator, 7

Safety of the Tools and Peripheral Devices, 10

Safety Precautions, 3

Safety Signals, 33

Servo Amplifier Module (A06B--6114--H205,A06B--6114--H302), 119

Servo Amplifiers, 117

Setting the Power Supply, 122

Signal Types, 209

Software Specifications, 213

Specifications of Digital Input/Output, 212

[T]Teach Pendant Cannot be Turned On, 28

Total Connection Diagram, 197

Transportation, 191

Transportation and Installation, 190

Treatment for the Shielded Cable, 189

Troubleshooting, 26

Troubleshooting Based on LED Indications, 96

Troubleshooting Using Fuses, 92

Troubleshooting Using the Error Code, 36

[V]Vibration Observed During Movement, 107

[W]Warning Label, 14

When the Robot is Connected to the CNC by a Pe-ripheral Device Cable, 171

Revision Record

FANUC Robot series R--J3iB Mate CONTROLLER For Europe MAINTENANCE MANUAL (B--81525EN--1)

01 Oct., 2001

Edition Date Contents Edition Date Contents

r-j3ib mate maintenance manual for europe b-81525en-1-01

Documents

replacing cards

replacing servo amplifiers

power supply unit

operator safety

led of power supply

backplane board unit

safety signals

safety precautions1